Lean manufacturing: The history and our time

2021 ◽  
Vol 17 (9) ◽  
pp. 1650-1669
Author(s):  
Ekaterina N. STRIZHAKOVA ◽  
Dmitrii V. STRIZHAKOV
Keyword(s):  
Production Process ◽  
Lean Manufacturing ◽  
Positive Impact ◽  
Manufacturing Sector ◽  
Lean Production ◽  
Economic Security ◽  
Production Model ◽  
Planning System ◽  
Industrial Enterprises ◽  
Production Concept

Subject. The article discusses the use of the lean production concept at the production enterprise. Objectives. We evaluate the existing lean production toolkit, determine opportunities for their implementation and possible difficulties. Methods. Methodologically, the study is based on the comparative analysis of methods that constitute the lean production system. Results. We review one of the economic security aspects for Russia, such as an increased production competitiveness due to the ubiquitous implementation and use of lean production instruments. We conducted an historical analysis of the origination and development of the production process approach. Some lean production tools and aspects were proved to have been designed and actively used in the USSR manufacturing sector since the 1960s. The lean production concept was found to become very appropriate for enterprises. We analyzed the continuing production planning system by A.S. Rodov, which were in use ans proved its high cost efficiency at the USSR industrial enterprises. We also delved into the profit generating production process that was put in place in Toyota. The article provides the comparative description of modern lean production methods and concludes on their future use. Conclusions. Having compared the Soviet lean production model and the classical Japanese one, we concluded on the use of such production process methods that really went beyond their time. In the mean time, the Soviet model was simpler to use and implement. Based on the overview of modern lean production tools that evolved from the Soviet and Japanese lean production theories, we believe that the lean production principles and methods will have a positive impact on the efficiency and competitiveness of the national manufacturing sector.

scholarly journals FEATURES OF THE LEAN PRODUCTION IMPLEMENTATION AT THE ENTERPRISES OF UKRAINE’S DAIRY INDUSTRY

2021 ◽  
Vol 2 (2) ◽  
pp. 48-53
Author(s):  
Mariia Foshchii ◽  
Natalia Krasnokutska
Keyword(s):  
Detailed Analysis ◽  
Lean Manufacturing ◽  
Lean Production ◽  
Rapid Assessment ◽  
Dairy Industry ◽  
Short Period ◽  
Analysis And Synthesis ◽  
Production Concept ◽  
Definition Of ◽  
Safe Working

The purpose of the paper is to study the features of the lean production implementation in the dairy industry of Ukraine. Methodology. To achieve the purpose and solve the tasks set in the paper, a system of general and special research methods was used, namely methods of scientific knowledge (scientific abstraction, analysis and synthesis, deduction, generalization) to study the theoretical principles of the lean production implementation in Ukraine’s enterprises, and questionnaire to assess the lean production implementation’s effectiveness in the enterprises of Ukraine’s dairy industry. Results of the survey examine the theoretical and methodological foundations of the “lean production” concept: taking into account all the definitions mentioned above, the following author’s definition of lean production is put forward: lean production is a system of the enterprise, which is constantly improving, aimed at building all processes in a continuous flow of value creation by preventing and eliminating all types of losses, involving staff in teamwork based on project approaches and maintaining safe working conditions in order to create attractive value for the consumer. Methodological support for rapid assessment of the lean production implementation’s effectiveness on the basis of employee surveys has been developed and the efficiency of the lean production implementation at the enterprises of Ukraine’s dairy industry has been assessed. It is concluded about the lack of effectiveness of implementing lean production at three enterprises of Ukraine’s dairy industry. This is due to the short period of the lean production implementation, as Enterprise 1 only started implementation at the end of 2020. Based on the survey and questionnaire of employees and managers of Ukraine’s dairy industry, the main stereotypes related to the implementation of lean production are identified and refuted, and the reasons for the slow and inefficient implementation of lean production are identified. Lean manufacturing cannot be implemented once and for all, it must be done constantly, because lean manufacturing is a tool for gaining a competitive advantage. Scientific novelty: methodological support for rapid assessment of the lean production implementation’s effectiveness has been further developed, which, unlike others, takes into account the peculiarities of the dairy industry and allows to determine problems and prospects for enterprise development on the basis of a questionnaire. A promising direction of research is a more detailed analysis of the “lean production polygon”, which is based on the survey. A more detailed analysis of the underlying three pentagons will reveal problems in the three subsystems of lean production.

scholarly journals Pivoting Lean Manufacturing through Industry 4.0 in the Indian Context

2019 ◽  
Vol 8 (2) ◽  
pp. 1-7
Author(s):  
Protik Basu ◽  
Pranab K. Dan
Keyword(s):  
Lean Manufacturing ◽  
Industry 4.0 ◽  
Industrial Revolution ◽  
Manufacturing Sector ◽  
Empirical Studies ◽  
Research Work ◽  
Production Model ◽  
Lean Management ◽  
Technological Developments ◽  
Indian Manufacturing Sector

Industry 4.0 and lean management both focus on increasing productivity of industrial systems. Industry 4.0 is foreseen to revolutionize today’s manufacturing environment whereas lean management is an integrated techno-operational system which has gained increasing importance in recent times to bring about a competitive state in an organization. Though in the last three decades there have been rigorous studies on lean manufacturing (LM), its implementation in the Indian manufacturing domain is still in its nascent stage. A lack of research to explore the potential use of Industry 4.0 is also noted. Research work on the compatibility of Industry 4.0 with LM is scarce and any study on the role of Industry 4.0 on LM in the Indian manufacturing sector is practically unavailable. The aim of this research is to explore how the fourth industrial revolution, referred to as Industry 4.0, can strategize LM in the Indian manufacturing context. Empirical studies have disclosed that Indian managers are hesitant to go for automation and technological developments. Results of this work reveal that there needs to be a change in attitude and approach. Lean implementers in India need to embrace Industry 4.0 to pivot LM by automating through Cyber-Physical Systems and creating a flexible design and production model of customized and smart products.

Applying Quality Function Deployment Techniques in Lead Production Project Selection and Assignment

2014 ◽  
Vol 945-949 ◽  
pp. 2954-2959 ◽  
Author(s):  
Chee Cheng Chen ◽  
Qing Zhang
Keyword(s):  
Lean Manufacturing ◽  
Quality Function Deployment ◽  
Lean Production ◽  
Production Performance ◽  
Great Opportunity ◽  
Pareto Chart ◽  
Quality Function ◽  
Lean Principles ◽  
Production Concept ◽  
Technical Solutions

In the past few decades’ lean production has become widely adopted in many industries, however there is still great opportunity to combine lean production with other methods or tools to reduce waste and improve production performance. QFD (Quality Function Deployment, QFD) is a combination of quality control and quality assurance methods that transform the customer's requirements into the technical aspects of response to the customer. "Lean" is derived from the Toyota Production System; Lean principles to eliminate waste. Many companies already use lean manufacturing and QFD methods, but can still not reach zero waste or fully reflect the needs of customers into new product designs. This study is based on the lean production concept to create a QFD model to reduce waste in the manufacturing process and reflect customer feedback. This article presents a literature review and then defines the QFD and lean manufacturing concepts and relationships. We use the Pareto chart to select the waste materials priority and build some technical solutions into the HOQ. Finally, this article provides lean concepts and QFD links and revises the standard manufacturing operating procedures (standard operation procedure, SOP). Management will be based on the newly revised SOP to improve waste management and further improve quality management.

scholarly journals Project Management for the Implementation of Lean Manufacturing at an Industrial Enterprise

2021 ◽  
Vol 2020 (4) ◽  
pp. 516-524
Author(s):  
Tatyana Belchik ◽  
Ilia Ezhov
Keyword(s):  
Project Management ◽  
Lean Manufacturing ◽  
Participant Observation ◽  
Lean Production ◽  
Production Methods ◽  
Scientific Methods ◽  
Industrial Enterprises ◽  
Business Units ◽  
Management Technology ◽  
Different Levels

The present research featured the implementation of lean manufacturing based on project management technology. The research objective was to substantiate the possibility of using tools and methods of lean production at industrial enterprises. The study involved such scientific methods as participant and non-participant observation, statistical methods, process modeling, and survey. At industrial enterprises, lean production methods should be implemented as a project activity, i.e. in different business units and at different levels. To achieve total inclusiveness, managers should be trained in the basics of project, and all other employees – in the basics of lean production. Even separate projects of lean production can increase efficiency and labor productivity. However, the use of certain tools often becomes an end in itself, and not a way to solve the actual problems. Employees involved in lean manufacturing projects often lack awareness and motivation. Insufficient experience in independent project slows down the implementation of lean production projects. Nevertheless, the authors proved that lean production projects can be effective if implemented properly. They also identified some problems specific to industrial enterprises and outlined activities that can improve operational efficiency.

scholarly journals TRANSITION TO THE BASIS OF THE CONCEPT OF LEAN PRODUCTION AS A SUCCESSION OF NEGATIVE TRENDS AT MINING ENTERPRISES AND METALLURGICAL COMPLEX OF UKRAINE (MESSAGE 2)

2018 ◽  
pp. 81-88 ◽  
Author(s):  
Mykola Myronenko
Keyword(s):  
Comparative Analysis ◽  
Lean Manufacturing ◽  
Lean Production ◽  
Metallurgical Industry ◽  
Management Decision ◽  
Practical Application ◽  
Production Concept

Purpose. Analysis of the features of the transition to the concept of lean production of enterprises of the mining and metallurgical complex (MMC) of Ukraine, located on the territory of the Dnipropetrovsk region. Prospects for the implementation of these approaches to 2020. Methodology. While writing the article, the following methods were used: questioning and interviews at the stage of collecting primary information, as well as the method of comparative analysis in justifying recommendations regarding the prospects for implementing the concept of lean production for the period up to 2020. Findings. The article analyzes the transition to the principles of the concept of lean production on the example of two enterprises of the MMC of Ukraine, geographically located within the Dnipropetrovsk region. The prospects for further implementation of the tools of the Lean Production concept for the period up to 2020 are considered. Originality. The importance of the practical application of methods and tools of the theory of the concept of lean manufacturing, in particular of the 5 C system and of the Submission of Proposals was confirmed. The necessity of applying various methods of auditing production activities was proved. This will optimize costs within the organization and affect the level of competitiveness of its products. Practical value. Understanding the fact that the company's profit is only an external manifestation of the correct management decision to minimize losses within the company will allow enterprises of the mining and metallurgical industry of Ukraine as a whole to progress.

scholarly journals Eliminating of lossesin the production process of a machine-building enterprise using lean manufacturing tools

2021 ◽  
Vol 58 (2) ◽  
pp. 5796-5801
Author(s):  
Natalya V. Prosvirina, Alexey I. Tikhonov, Hilary I. Okagbue
Keyword(s):  
Problem Solving ◽  
Production Process ◽  
Value Creation ◽  
Lean Manufacturing ◽  
Lean Production ◽  
Machine Building ◽  
Engineering Plant ◽  
Current State ◽  
Engineering Company ◽  
Identification Analysis

The article examines the sequence of actions to eliminate losses in the production process with the help of lean production tools at the Russian engineering plant. At the same time, the tasks are solved: the stages of the process of identification, analysis and problem solving are analyzed, the algorithm of elimination of losses in the production process is shown, an algorithm is proposed to build a map of the flow of the value creation of the current state of the production process of the manufacture of the part, the tools of lean production to eliminate the main losses are presented.  With the systematic and concerted development of these tools, with the active advice and support of the management of the engineering company, the management of the production process on the basis of the concept of lean production allows to reduce losses, help to grow and develop the plant.

DEVELOPMENT OF PRINCIPLES FOR INTEGRATION OF QUALITY MANAGEMENT SYSTEMS AND LEAN MANUFACTURING OF INDUSTRIAL ENTERPRISES

2021 ◽  
pp. 34-38
Author(s):  
V. F. Bezyazychzny ◽  
E. V. Kiselev ◽  
K. I. Kotova
Keyword(s):  
Quality Management ◽  
Lean Manufacturing ◽  
Quality Management System ◽  
Integrated Management ◽  
Lean Production ◽  
Iso 9000 ◽  
National Standards ◽  
Enterprise Management ◽  
Quality Management Systems ◽  
Industrial Enterprises

The activities of many enterprises are regulated by the requirements of national standards in the field of quality management, lean production, environmental management and labor protection. Despite the fact that these standards are oriented as independent subsystems of enterprise management, they have common elements, the implementation of which can be integrated. The article presents an analysis of the identity of the principles of the quality management system and the lean production system, regulated by GOST R ISO 9000–2015, GOST R 56020–2014 and GOST R ISO 10006–2005. Proposals are given for creating integrated management principles taking into account the requirements of GOST R 53893–2010, GOST R 55269–2012 and GOST R 57522–2017.

scholarly journals Change management practices to support the implementation of lean production systems: a survey of the scientific literature

2020 ◽  
Vol 27 (2) ◽  
Author(s):  
Isadora Avelar Ferreira ◽  
Fernando Oliveira de Araujo ◽  
Márcia Elisa Soares Echeveste
Keyword(s):  
Literature Review ◽  
Change Management ◽  
Production System ◽  
Lean Manufacturing ◽  
Management Practices ◽  
Production Systems ◽  
Lean Production ◽  
Production Model ◽  
Operational Strategies ◽  
The People

Abstract: The transition from mass production system to lean production system carrier significant changes in operational strategies of industrial organizations. A production model system can engender different reactions by the people involved; some of them can show resistance during the process, ranging from unreserved support to a hidden resistance (even explicit). In order to identify the main practices to support change processes, this study provides a literature review to systematize the main researches related to change management during lean manufacturing implementation. This study aims to provide a systematic literature review covering main researches related to change management and lean manufacturing implementation to identify the main factors that affect the production system change. The research was carried out between October 2016 and January 2018. In methodological terms, literature review was developed by using Scopus and ISI web of Science publications. As a result of this study, 25 papers related to lean manufacturing implementation were identified and 10 factors were consolidated. The most relevant practices of change management were also identified to support lean production system implementation.

scholarly journals Improvement of Production Processes with the Use of Lean Manufacturing Tools

2018 ◽  
Vol 1 (1) ◽  
pp. 529-535 ◽  
Author(s):  
Joanna Furman ◽  
Marzena Kuczyńska-Chałada ◽  
Roksana Poloczek
Keyword(s):  
Lean Manufacturing ◽  
Necessary Conditions ◽  
Lean Production ◽  
Continuous Development ◽  
Industrial Enterprises ◽  
Manufacturing Management ◽  
Production Processes ◽  
Model Of Management ◽  
Strong Position ◽  
Exact Product

Abstract Growing competition, clients’ requirements as well as advances in technology make modern industrial enterprises search for a way of achieving and maintaining strong position on the market. One of the principal and at the same time necessary conditions to achieve this aim is continuous development of all of the processes in order to fulfil various clients’ expectations. Enterprises make use of different concepts and management methods which in significant way upgrade ongoing processes by raising their efficiency. One of such is the concept of ‘lean’ production - Lean Manufacturing. Management according to Lean Management rules allows to produce more with the use of less resources - at the same time approaching the aim which is to deliver clients the exact product they want. The process of resources use limitation is not easy to perform however, the concept of Lean Manufacturing by the application of chosen tools allows successfully and effectively to introduce ‘lean’ model of management in an enterprise and undertaking following improvement activities in every of its field.

scholarly journals Lean manufacturing as a tool for increasing labor productivity at the enterprise

2019 ◽  
Vol 124 ◽  
pp. 04015 ◽  
Author(s):  
N. Ketoeva ◽  
N. Soldatova ◽  
S. Ilyashenko
Keyword(s):  
Lean Manufacturing ◽  
Lean Production ◽  
Point Of View ◽  
Company Performance ◽  
Production Methods ◽  
Second Stage ◽  
Stage Of Development ◽  
Third Stage ◽  
Production Concept ◽  
Market Indicator

Since the beginning of utilization of the lean production concept it has passed several stages of implementation. The first stage failed because manufacturers that introduced lean production methods were isolated from each other; whereas in the second stage, these companies learned from their experiences. Since then, the lean production concept has been used to organize production and reduce costs, despite the fact that markets are becoming more demanding due to individualization of demand and variability of conditions. Digitalization suggests methods for adapting the concept of lean production to such a market indicator as company performance. Thus, the utilization of the concept “Industry 4.0” can initiate the third stage of development of the practice of lean manufacturing in terms of analyzing the productivity from a multidimensional point of view.

Sign in / Sign up

Export Citation Format

Share Document