Impact of longer usage of lean manufacturing system (Toyotism) on employment outcomes - a study in garment manufacturing industries in India

2014 ◽  
Vol 18 (3) ◽  
pp. 305 ◽  
Author(s):  
Prageetha G. Raju ◽  
Madhuri Modekurti Mahato
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing System ◽  
Employment Outcomes ◽  
Manufacturing Industries ◽  
Garment Manufacturing

A Framework for Implementing Lean Manufacturing System in Small and Medium Enterprises

2011 ◽  
Vol 110-116 ◽  
pp. 3997-4003 ◽  
Author(s):  
Jirapat Wanitwattanakosol ◽  
Apichat Sopadang
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing System ◽  
Job Shop ◽  
Small And Medium Enterprises ◽  
Phase 1 ◽  
Optimization Technique ◽  
Value Stream Mapping ◽  
Two Phase ◽  
Make To Order ◽  
Medium Enterprises

—In this paper, a conceptual framework to apply many techniques for implementing lean in the high-variety low-volume (HVLV) environment is presented. Lean production has increasingly being implemented as a potential solution for many organizations. Anyway, the lean formula is applicable directly only to the make-to-stock business, but the make-to-order (MTO) product environment has to adapt lean manufacturing principle. The method of this paper has a two-phase quantitative framework to transform small and medium enterprises (SMEs) to be lean. Phase 1 has three interrelated components: (1) re-engineering an organization by using the power of computer simulation combined with business process. (2) Value stream mapping (VSM) is used to create a map of both value and waste in a given process. This tool has also a main drawback for job shop facility because many value streams are composed of hundreds of industrial parts and products. (3) Integrative supplier relationship is one of the most critical factors to maintain an advantage in the increasing levels of competition. Phase 2 performs a just in time production schedule by using ant colony optimization technique combines with a simulation tool. The aims of this paper are to develop a suitable lean manufacturing system for SMEs and to study the performance of the system for improving effectiveness. The result shows how to combine lean concept with simulation optimization, the step of this framework to obtain the optimization solution.

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.

Validity and reliability of lean manufacturing frameworks

2014 ◽  
Vol 5 (4) ◽  
pp. 361-391 ◽  
Author(s):  
Naga Vamsi Krishna Jasti ◽  
Rambabu Kodali
Keyword(s):  
Frequency Analysis ◽  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Research Work ◽  
Middle Level ◽  
Manufacturing Industries ◽  
Validity And Reliability ◽  
Content Type ◽  
Survey Tool ◽  
Industry Sector

Purpose – The purpose of this paper is to investigate, validity and reliability analysis on existing Lean manufacturing (LM) frameworks when applied to Indian organizations. LM is one of the best manufacturing strategies that are used by manufacturing plant managers to improve manufacturing capabilities. Design/methodology/approach – In the present research work, a questionnaire-based survey was used to examine 35 LM frameworks. The study targeted respondents ranging from top- and middle-level management personnel in Indian manufacturing industry. The sample includes organizations in a variety of industries ranging from automobile, electronics, engineering, process and textile industries products. The survey tool was prepared with team of 12 members i.e. six academicians and six professionals from manufacturing industry environment. The study received 186 responses from various sectors of manufacturing industry, 180 surveys were usable resulting in a response rate of 23.90 per cent. Factor analysis was conducted to check unidimentionality of the framework. Cronbach’s alpha is calculated to find reliability of each framework’s. Lastly, frequency analysis was used to recognize familiar constructs of LM on the chosen framework. Findings – This study has identified that most of the LM frameworks revealed a high level of reliability. When the study has examined further advance about unidimensionality with respect to the construct, i.e. the LM it measures, it confirmed 11 frameworks were revealing unidimensionality. The frequency analysis was evident that a greater part of the constructs has a high mean score and mode. Finally, the research concludes that there is requirement for a novel framework to Indian manufacturing industry to stay in competition with global manufacturing industries. Research limitations/implications – Cross-sectional data from manufacturing industries and India (only one country) is used with sample size restricted to 180 only, and it would be interesting to test these frameworks for more than one industry sector and country. Practical implications – The present work tries to find the suitability of the presented LM frameworks to Indian manufacturing industry sector. The authors hoped that the present research would give the information to the management to execute the suitable LM framework in their firm. Originality/value – The present work tries to find the suitability of the presented LM frameworks to Indian manufacturing industry sector. The authors hoped that the present research would give the information to the management to execute the suitable LM framework in their firm.

scholarly journals Implementation of 5S in Manufacturing Industry: A Case of Foreign Workers in Melaka

2018 ◽  
Vol 150 ◽  
pp. 05034 ◽  
Author(s):  
San Chee Houa ◽  
M. Haslinda ◽  
Sedek Muliati ◽  
Abdullah Mariam Miri ◽  
A. F. Rahim
Keyword(s):  
Lean Manufacturing ◽  
Quantitative Methods ◽  
Manufacturing Industry ◽  
Manufacturing System ◽  
Research Study ◽  
Foreign Workers ◽  
Main Role ◽  
Cross Sectional ◽  
Descriptive Research ◽  
Barriers To Implementation

Lean manufacturing system has been infiltrated in manufacturing sectors across the world. In fact, Lean manufacturing system is a practice which regards the use of the resources, creation of value for the end customers, and as the ways to eliminate the waste. There are several tools that can be used to eliminate the waste within the industry. This research is a study of the implementation of 5S in manufacturing industry. Despite this, the research study focused on manufacturing industry, which has been implemented 5S system in Melaka State. Although there are number of tools and technique available to help in improving the manufacturing process, however, there is only few industries could implement the tools successfully. In this research, foreign workers play a main role in implement the 5S systems as the manufacturing industry in Malaysia adopt large amount of foreign workers to work as employees. Therefore, it is important to ensure the foreign workers truly understand the concept of 5S system and adopt the best ways to implement it in order to have better performance. This research study has been proposed by the research model of the barriers to implementation of 5S in manufacturing industry among foreign workers. A several research method has been adopted to do the research, such as descriptive research design with quantitative methods, survey questionnaire and cross-sectional studies.

A Waste Elimination Process

2020 ◽  
pp. 567-598
Author(s):  
Sherif Mostafa ◽  
Jantanee Dumrak
Keyword(s):  
Continuous Improvement ◽  
Lean Manufacturing ◽  
Manufacturing System ◽  
Important Task ◽  
Elimination Process ◽  
Green Waste ◽  
Waste Removal ◽  
Waste Elimination ◽  
Process Structure

The continuous improvement using waste elimination has been emphasized as the most important task of modern organizations. Lean manufacturing system has proved its capability to eliminate waste and produce environmental gains. The eight types of waste identified under lean have positive relations to green waste. In this chapter, a waste elimination process is suggested as an approach for lean sustainable outcomes. The process structure contains three consecutive phases: waste documentation, waste analysis, and waste removal. The techniques and tools of each phase are inclusively discussed.

An application of grey based decision making approach for the selection of manufacturing system

2014 ◽  
Vol 4 (3) ◽  
pp. 447-462 ◽  
Author(s):  
Om Ji Shukla ◽  
Gunjan Soni ◽  
G. Anand
Keyword(s):  
Decision Making ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Strategic Decision ◽  
Decision Matrix ◽  
Content Type ◽  
Manufacturing Organization ◽  
Decision Making Model ◽  
Selection Of

Purpose – In the current customer-driven market, the manufacturers have to be highly responsive and flexible to deliver a variety of products. Hence, to meet this dynamic and uncertain market changes, the production system, which enables the manufacturing of such variety of products should be able to meet such diverse, dynamic changes. Hence, selecting a suitable manufacturing system is a key strategic decision for today's manufacturing organization, which needs to survive in these uncertain market conditions. Hence, the purpose of this paper is to present a decision-making model for selecting the best manufacturing system and also discuss the criteria on the basis of which the management can select the same. Design/methodology/approach – A case of small- and medium-sized company is presented, in which the management is deciding to establish a most suitable manufacturing system. To supplement this, a suitable multi-criteria decision-making model (MCDM), the grey approach is used to analyze manufacturing system alternatives based on various decision criteria to arrive a comparative ranking. Findings – An extensive analysis of grey-based decision-making model described grey decision matrix, grey normalized decision matrix, grey weighted normalized decision matrix and grey possibility degrees for three alternatives revealed that lean manufacturing systems was found to be the most suitable manufacturing system among three alternatives for a given case. Research limitations/implications – The same study can be extended by including sub-criteria with main criteria for selection of manufacturing system by utilizing two MCDM techniques such as AHP or ANP with Grey approach. Practical implications – The Grey approach has been discussed in a detailed way and it will be useful for the managers to use this approach as a tool for solving similar type of decision-making problems in their organizations in the future. Originality/value – Although, the problem of selecting a suitable manufacturing system is often addressed both in practice and research, very few reports are available in the literature of Grey-based decision models that demonstrated its application for selecting a suitable manufacturing systems.

Study of Industry 4.0 and its Impact on Lean Transformation in Aerospace Manufacturing

2019 ◽  
Author(s):  
Sagil James ◽  
Alejandro Cervantes
Keyword(s):  
Lean Manufacturing ◽  
Industry 4.0 ◽  
Manufacturing Sector ◽  
Discrete Event ◽  
Hybrid Approach ◽  
Manufacturing Industries ◽  
Lean Principles ◽  
Aerospace Manufacturing ◽  
Lean Transformation

Abstract Lean manufacturing practices focus on minimizing all forms of waste from the production system. The applicability of lean manufacturing concepts and principles has often been questioned in sectors including aerospace manufacturing primarily due to their high variety - low volume environments. The key challenges include the difficulty in changing the factory layout, lack of plant-specific manufacturing strategies, lack of benchmarking between manufacturing plants and non-existence of learning through experimentation culture. Consequently, the aerospace manufacturing industries have struggled to implement lean principles over the years successfully. Industry 4.0 is a new paradigm that is significantly influencing several manufacturing industries across the globe. Applying the concepts of Industry 4.0 along with the conventional lean transformation technology could potentially address these challenges. The focus of this research is to study the possibilities of integrating Industry 4.0 tools with existing lean manufacturing philosophies within the aerospace manufacturing sector in order to improve various aspects of manufacturing processes in a cyber-physical environment. A case study is performed considering a quality inspection department in a typical aerospace industry. The case study is simulated using discrete event simulation tool — Arena. The study found that a hybrid approach involving the holistic merger of the lean principles along with the Industry 4.0 tools known as Lean Industry 4.0 is the best way forward for the aerospace manufacturing sector. The outcomes of this research provide an understanding of the role of industry 4.0 paradigm and their implementation in several other high-technology and high-risk manufacturing sectors including life sciences, space, and defense industries.

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