Mapping of non-value adding activities occurring in classical manufacturing companies with lean strategies

2021 ◽  
pp. 095440892110515
Author(s):  
D Ramesh Kumar ◽  
S R Devadasan ◽  
D Elangovan
Keyword(s):  
Critical Thinking ◽  
Lean Manufacturing ◽  
Successful Implementation ◽  
Careful Study ◽  
Manufacturing Companies ◽  
Manufacturing Organizations ◽  
In The Beginning

In the literature arena, it is claimed that lean manufacturing has been implemented successfully in organizations. However, lean manufacturing has been finding little application in classical manufacturing organizations. A careful study of the literature would indicate that non-value adding activities have been occurring in classical manufacturing organizations and preventing the successful implementation of lean manufacturing. In order to overcome this deficient situation, the research reported in this paper was carried out. By carrying out this research, non-value adding activities were mapped with lean manufacturing strategies. In the beginning, 50 non-value adding activities and 27 lean manufacturing strategies were gathered from the literature arena. Through critical thinking, the non-value adding activities were mapped with lean manufacturing strategies. The list containing this map presented in this paper will be useful to the engineers and managers for successfully implementing lean manufacturing in classical manufacturing organizations.

SOFT LEAN PRACTICES FOR SUCCESSFUL LEAN PRODUCTION SYSTEM IMPLEMENTATION IN MALAYSIA AUTOMOTIVE SMES: A PROPOSED FRAMEWORK

2015 ◽  
Vol 77 (27) ◽  
Author(s):  
Rusalbiah Che Mamat ◽  
Baba Md Deros ◽  
Mohd Nizam Ab Rahman ◽  
Muhamad Khalil Omar ◽  
Shukriah Abdullah
Keyword(s):  
Automotive Industry ◽  
Production System ◽  
Lean Manufacturing ◽  
Success Factors ◽  
Lean Production ◽  
Business Environment ◽  
Successful Implementation ◽  
Manufacturing Companies ◽  
Lean Implementation ◽  
Lean Practices

Challenging and competitive business environment has prompted the automotive industry to restructure its manufacturing practices. Nowadays, Lean Manufacturing (LM) has been widely implemented in the automotive industry. LM supported the manufacturing companies, particularly automotive manufacturers in becoming world class manufacturers through various lean practices. However, lean implementation faced various obstacles such as the lack of management commitment and support, the absence of organizational communication, employees’ attitude and many more. It is also indicated that lean implementation success factors are not merely due to technical practices but also with the integration of non-technical aspects such as human-related practices. This paper aims to investigate the Soft Lean Practices that are necessary for the successful implementation of the Lean Production System (LPS) in the Malaysian Automotive SMEs. The result of this paper will provide a detailed review of Soft Lean Practices within the LM literature that should be considered by the organizations when implementing lean. A framework was also developed through an extensive review of Soft Lean literature.

scholarly journals Measuring Lean Culture: Designing a Research Instrument

2021 ◽  
Vol 5 (1) ◽  
pp. 7-17
Author(s):  
Azim Azuan Osman ◽  
Norani Nordin ◽  
Mohd Faizol Abd Rahman
Keyword(s):  
Lean Manufacturing ◽  
Structural Equation ◽  
Manufacturing System ◽  
Manufacturing Companies ◽  
Research Instrument ◽  
Manufacturing Organizations ◽  
Lean Transformation ◽  
Culture Characteristics ◽  
Ultimate Result ◽  
Operational Excellence

Transformation from conventional manufacturing system to lean manufacturing system has enabled many manufacturing companies to reduce waste and ultimately achieve operational excellence. Unfortunately, there were also many reported cases where manufacturers failed to sustain the transformation until they achieve the ultimate result. Converting organization’s culture into the lean culture is often claimed as one of the mechanisms to sustain lean transformation in manufacturing organizations. Thus, measuring to what level lean manufacturers have converted their organization’s culture relative to lean culture characteristics is critical. Selfadministered questionnaire is a practical research instrument to measure the level of lean culture in multiple manufacturing organizations that are located in far-reaching geographical as it saves time, money and effort. In this paper, 36 questionnaire items for measuring lean culture has been designed. These items can be used as parameters for predicting sustainability of lean transformation using statistical analysis such as linear regression or structural equation modelling.

Ghana: the State of Agriculture and Prospects for Food Security in the Context of Achieving SDGs

2018 ◽  
pp. 16-31
Author(s):  
Tatyana Denisova
Keyword(s):  
Food Security ◽  
Socioeconomic Development ◽  
Agricultural Sector ◽  
Well Being ◽  
The State ◽  
Successful Implementation ◽  
Careful Study ◽  
African Countries ◽  
Development Goals ◽  
The Government

For the first time in Russian African studies, the author examines the current state of agriculture, challenges and prospects for food security in Ghana, which belongs to the group of African countries that have made the most progress in achieving the Sustainable Development Goals (SDGs). The SDGs are a collection of 17 global goals adopted by UN member states in 2015 with a view of achieving them by 2030. The SDGs include: ending poverty in all its forms everywhere (Goal 1); ending hunger, achieving food security and improved nutrition, and promoting sustainable agriculture (2); ensuring healthy lives and promoting well-being for all at all ages (3), etc. These goals are considered fundamental because the achievement of a number of other SDGs – for example, ensuring quality education (4), achieving gender equality (5), ensuring sustainable consumption and production patterns (12), etc. – largely depends on their implementation. Ghana was commended by the world community for the significant reduction in poverty, hunger and malnutrition between 2000 and 2014, i.e. for the relatively successful implementation of the first of the Millennium Development Goals (MDGs, 2000–2015) – the eradication of extreme poverty and hunger. However, SDGs require more careful study and planning of implementation measures. In order to achieve the SDGs, the Government of Ghana has adopted a number of programs, plans and projects, the successful implementation of which often stumbles upon the lack of funding and lack of coordination between state bodies, private and public organizations, foreign partners – donors and creditors, etc., which are involved in the processes of socioeconomic development of Ghana. The author determines the reasons for the lack of food security in Ghana, gives an assessment of the state of the agricultural sector, the effective development of which is a prerequisite for the reduction of poverty and hunger, primarily due to the engagement of a significant share (45%) of the economically active population in this sector. The study shows that the limited growth in food production is largely due to the absence of domestic markets and necessary roads, means of transportation, irrigation and storage infrastructure, as well as insufficient investment in the agricultural sector, rather than to a shortage of fertile land or labor.

scholarly journals Operations management body of knowledge and its relevance to manufacturing and service organizations

2018 ◽  
Vol 25 (4) ◽  
pp. 373-389 ◽  
Author(s):  
Jurandir Peinado ◽  
Alexandre Reis Graeml ◽  
Fernando Vianna
Keyword(s):  
Operations Management ◽  
Lean Manufacturing ◽  
Process Management ◽  
Work Organization ◽  
The Body ◽  
Service Organizations ◽  
Manufacturing Companies ◽  
Content Type ◽  
Service Companies ◽  
Body Of Knowledge

Purpose The purpose of this paper is to assess the differences in importance assigned by manufacturing or service organizations to topics related to operations management and its attendant body of knowledge. Design/methodology/approach The authors did this by cataloguing and analyzing vacancy announcements related to operations management, presented by manufacturing and services companies in major Brazilian human resources websites. Findings The results show that manufacturing companies primarily hire personnel with skills in routine process management, quality management, lean manufacturing, ergonomics and work organization. Service companies generally seek professionals with knowledge and experience in logistics, supply chain management and project management. Research limitations/implications This study presents some limitations that reduce the power of its conclusions. There is some degree of subjectivity in the interpretation of the contents of the analyzed ads. In order to reduce this problem, the authors who did the tabulation of data marked the situations for which there were some doubts about the classification, discussing them with the other author, until they reached a consensus on the best way to classify each one. Originality/value The discussion about the importance assigned by manufacturing and service companies to the topics of operations management is crucial for not only the results obtained, but also to stimulate the debate on topics that comprise or should comprise the body of knowledge of operations management, and the way they are incorporated into business practice. This provides an additional opportunity to reflect on the potential of operations management in supporting business managers now and in the future.

Integration of the concept of lean manufacturing and digital technologies of high-tech enterprises in modern conditions

2020 ◽  
pp. 105-113
Author(s):  
Н.С. Хорошавина ◽  
М.С. Абрашкин
Keyword(s):  
Lean Manufacturing ◽  
Process Management ◽  
Business Processes ◽  
Digital Technologies ◽  
Balance Of Power ◽  
Global Market ◽  
High Tech ◽  
Successful Implementation ◽  
Modern Business ◽  
Business Conditions

Цифровые технологии существенно влияют на мировой рынок, внося коррективы в расстановку сил на нем. Используемые ранее подходы к управлению бизнес-процессами становятся не актуальными в современных условиях. Без цифровизации наукоемкие производства будут не способны выдержать конкурентную борьбу, и вынуждены будут уйти с рынка. В то же время современные условия хозяйствования диктуют необходимость постоянного совершенствования бизнес-процессов наукоемких предприятий, их оптимизации. Данные принципы являются основой концепции бережливое производство, реализация которых становится более эффективной при условии использования цифровых технологий. В статье рассмотрены вопросы интеграции концепции бережливое производство и цифровых технологий на наукоемких предприятиях. Показан пример успешной реализации принципов данной концепции с использованием цифровых подходов к оптимизации бизнес-процессов наукоемкого производства. В современных условиях важнейшим активом любого предприятия, в том числе и наукоемкого производства, являются данные. Реализация принципов бережливого производства требует обработки значительного объема информации. Цифровые технологии позволяют анализировать информационные потоки в режиме реального времени, моделировать бизнес-процессы и тем самым, способствуют более качественному и оперативному принятию решений по оптимизации бизнес-процессов наукоемких производств. Только объединив принципы концепции бережливое производство и возможности, которые дает цифровизация, наукоемкие предприятия смогут не просто удержать свои конкурентные позиции на рынке, но и перейти на более качественный уровень своего развития. Digital technologies significantly affect the global market, making adjustments to the balance of power in it. Previously used approaches to business process management are no longer relevant in modern conditions. Without digitalization, high-tech industries will not be able to withstand competition and will be forced to leave the market. At the same time, modern business conditions dictate the need to constantly improve the business processes of high-tech enterprises and optimize them. These principles are the basis of the concept of lean manufacturing, the implementation of which becomes more effective when using digital technologies. The article deals with the integration of the concept of lean manufacturing and digital technologies in high-tech enterprises. An example of successful implementation of the principles of this concept using digital approaches to optimizing business processes in high-tech production is shown. In modern conditions, the most important asset of any.

A systematic literature review of lean manufacturing implementation in manufacturing-based sectors of the developing and developed countries

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Catherine Maware ◽  
Modestus Okechukwu Okwu ◽  
Olufemi Adetunji
Keyword(s):  
Developing Countries ◽  
Literature Review ◽  
Lean Manufacturing ◽  
Negative Impact ◽  
Developed Countries ◽  
Manufacturing Industries ◽  
Preliminary Review ◽  
Content Type ◽  
Manufacturing Organizations ◽  
Developing And Developed Countries

Purpose This study aims to comparatively discuss the effect of lean manufacturing (LM) implementation in the manufacturing sectors of developing and developed countries. Design/methodology/approach An in-depth literature review focused on previous research published between 2015 and March 2020. The papers published by the databases such as Google Scholar, Scopus, ProQuest and Web of Science were used in the study. A total of 63 studies that focused on LM application in manufacturing industries in developing and developed countries were used in the research. Findings It was observed that LM improves operational performance for manufacturing organizations in developing and developed countries. Small and medium-sized enterprises in both developed and developing countries have difficulties transforming their organizations into lean organizations compared to large enterprises. Furthermore, the review also found that there seems to have been no paper had reported the negative impact of implementing LM in manufacturing industries in developing and developed countries from 2015 to March 2020. Research limitations/implications The study used research papers written between January 2015 and March 2020 and only considered manufacturing organizations from developed and developing nations. Practical implications The study provides more insight into LM implementation in developing and developed countries. It gives the LM practices and the implications of applying these practices in manufacturing organizations for developing and developed countries. Originality/value A preliminary review of papers indicated that this seems to be the first paper that comparatively studies how LM implementation has affected manufacturing organizations in developed and developing countries. The study also assessed the LM practices commonly used by the manufacturing industries in developing and developed countries.

Analysis of interaction among the barriers to 5S implementation using interpretive structural modeling approach

2017 ◽  
Vol 24 (7) ◽  
pp. 1834-1853 ◽  
Author(s):  
Rajesh Attri ◽  
Bhupender Singh ◽  
Sunil Mehra
Keyword(s):  
Structural Equation ◽  
Structural Model ◽  
Structural Modeling ◽  
Equation Modeling ◽  
Successful Implementation ◽  
Interpretive Structural Modeling ◽  
Content Type ◽  
Modeling Approach ◽  
Manufacturing Organizations ◽  
Top Management Commitment

Purpose The purpose of this paper is to ascertain and analyze the interactions among different barriers of 5S implementation in manufacturing organizations. Design/methodology/approach In this paper, 15 barriers affecting the implementation of 5S in manufacturing organizations have been identified from literature analysis and discussion with academic and industrial experts. Afterwards, identified barriers were validated by using nation-wide questionnaire-based survey. Then, interpretive structural modeling (ISM) approach has been utilized to find out the interaction among the identified barriers in order to develop hierarchy-based model. Findings The research identifies several key barriers which have high driving power and weak dependence power. In this concern, these barriers entail extreme care and handling for successful implementation of 5S. Financial constraints, lack of top management commitment, and no proper vision and mission are found to be the key barriers. Research limitations/implications The developed ISM model is based on experts’ opinion. This developed hierarchy-based model requires further validation by using structural equation modeling approach or by performing detailed case studies. Originality/value In this paper, ISM-based structural model has been recommended for Indian manufacturing organizations, which is a novel exertion in the area of 5S implementation.

scholarly journals Strategic Groups and Competitive Priorities in Lean Production Environments: Challenges of Production Management

2018 ◽  
Vol 18 (2) ◽  
Author(s):  
Orlando Roque Da Silva ◽  
Delvio Venanzi ◽  
Haroldo Lhou Haegawa ◽  
Diogo Faustino
Keyword(s):  
Lean Manufacturing ◽  
Production Management ◽  
Lean Production ◽  
Manufacturing Companies ◽  
Strategic Groups ◽  
Strategic Orientations ◽  
Production Environments ◽  
Auto Parts ◽  
Production Practices ◽  
The Relationship

This paper explores how the choices and implementation of lean production practices are influenced by performance goals prioritized by firms in the context of operations strategy. We analyzed a set of fifty-six companies in the auto parts industry in Campinas and Jundiai region, divided into four strategic groups. These groups of firms that adopt similar strategic orientations were used to investigate the relationship between implementation of lean manufacturing practices and choice of performance objectives. The results suggest that consideration of strategic groups can improve the understanding of how performance objectives can define lean manufacturing practices adopted by manufacturing companies.

scholarly journals Energy Analysis via Value Stream Mapping: A case study of an Automotive Weld Plant

ORiON ◽  
2021 ◽  
Vol 37 (2) ◽  
Author(s):  
Keshav Ramsunder ◽  
Oludolapo Olanrewaju
Keyword(s):  
Lean Manufacturing ◽  
Sustainable Manufacturing ◽  
Environmental Benefits ◽  
Value Stream Mapping ◽  
Measuring Instruments ◽  
Manufacturing Companies ◽  
Step Method ◽  
Empirical Observation ◽  
Value Stream ◽  
Starting Point

Over the past few decades, Lean Manufacturing (LM) has been the pinnacle of strategies applied for cost and waste reduction. However as the search for competitive advantage and production growth continues, there is a growing consciousness towards environmental preservation. With this consideration in mind this research investigates and applies Value Stream Mapping (VSM) techniques to aid in reducing environmental impacts of manufacturing companies. The research is based on empirical observation within the Chassis weld plant of Company X. The observation focuses on the weld operations and utilizes the cross member line of Auxiliary Cross as a point of study. Using various measuring instruments to capture the emissions emitted by the weld and service equipment, data is collected. The data is thereafter visualised via an Environmental Value Stream Map (EVSM) using a 7-step method. It was found that the total lead-time to build an Auxiliary Cross equates to 16.70 minutes and during this process is emitted. It was additionally found that the UPR x LWR stage of the process indicated both the highest cycle time and carbon emissions emitted and provides a starting point for investigation on emission reduction activity. The EVSM aids in the development of a method that allows quick and comprehensive analysis of energy and material flows. The results of this research are important to practitioners and academics as it provides an extension and further capability of Lean Manufacturing tools. Additionally, the EVSM provides a gateway into realising environmental benefits and sustainable manufacturing through Lean Manufacturing.

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