Lean Production Weaknesses in Manufacturing Industry: A Review

2015 ◽  
Vol 735 ◽  
pp. 344-348 ◽  
Author(s):  
K.K Nithia ◽  
Mohd Yusof Noordin ◽  
Muhamad Zameri Mat Saman
Keyword(s):  
Production System ◽  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Review Paper ◽  
Lean Production ◽  
Agile Manufacturing ◽  
Review Literature ◽  
Shop Floor ◽  
Automotive Manufacturing ◽  
Manufacturing Sectors

This is a review paper written to discuss the lean manufacturing and the lean weaknesses in manufacturing industry. Lean production or also known as lean manufacturing has been widely practiced as a production improvement tool in manufacturing sectors. Lean manufacturing originated from Japanese automotive manufacturing sectors for about five decades. Over the decades, lean production system have evolved from shop floor improvement tool to a philosophy. The problem statement in this research was to review the weaknesses of lean production system. The purpose of this review paper is to discuss the weaknesses of the lean production system and overview the available methods to address the weaknesses. Limitation and scope of this paper were within manufacturing industry and period of literature reviews. The methodology applied was review literature from the lean manufacturing related journals dated from year 2000 to 2014. Then by consolidating the lean production weaknesses data in to categories of people, material, equipment, know-how, business and planning or scheduling. The authors discussed to elaborate further on the lean weaknesses and methods of addressing it. Therefore, understanding the weaknesses will allow the academic and industry to co-create new solution methods for an effective lean production system. In conclusion, the authors view the weaknesses as an opportunity to integrate with other theories such as agile manufacturing, sustainable development, human factor, safety management and cleaner production in the future.

scholarly journals Industrial Case Study on Lean Manufacturing Implemented on Manufacturing Polypropylene Ropes Industry Amravati

2021 ◽  
Vol 9 (12) ◽  
pp. 1318-1323
Author(s):  
Vipul Deshpande
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Service Industry ◽  
Developing Economies ◽  
Labour Productivity ◽  
Shop Floor ◽  
Industrial Case Study ◽  
Lean Principles ◽  
Manufacturing Techniques

Abstract: Lean manufacturing has been one of the most standard method in the manufacturing and service industry for elimination of waste. Every manufacturing industry has to put in continuous effort for its survival in the current impulsive and competitive economy. The purpose of this paper is to investigate the adoption of lean manufacturing tools and techniques in the manufacturing industries. This paper is based on actual implementation of lean manufacturing techniques. It focuses on the execution of flow from the start until the end of the implementation, types of analysis and tools applied, evaluation methods and how the industry benefited from the implementation. In this case study we particularly focused on Shop floor management, Quality Management (QM), Supplier and Customer Management (SCM) and Workforce Management (WM). After going through various testing on implementation of Lean Manufacturing principles in Micro Small medium Enterprise (MSME), researcher studied thoughts of some author where they discussed pragmatic problems they overcome while implementing lean principles in developing economies MSME. At the end, the result shows that there is monthly increment in capital productivity and labour productivity. And decrement in inhouse rejection, breakdown hours and customer complaint from the implementation of lean.

An investigation into manufacturing performance achievements accrued by Indian manufacturing organization through strategic 5S practices

2018 ◽  
Vol 67 (4) ◽  
pp. 754-787 ◽  
Author(s):  
Jugraj Singh Randhawa ◽  
Inderpreet Singh Ahuja
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Service Industry ◽  
Manufacturing Sector ◽  
Successful Implementation ◽  
Automotive Manufacturing ◽  
Content Type ◽  
Manufacturing Performance ◽  
Improvement Programs ◽  
Manufacturing Organization

Purpose The purpose of this paper is to evaluate the quantitative and qualitative benefits accrued by an Indian automotive parts industry through strategic 5S implementation initiatives. Design/methodology/approach The study involves evaluation of steps involved in systematic implementation of 5S program methodology in an automotive manufacturing organization and investigation of achievements accrued by the industry through the successful implementation of 5S program. Findings The empirical results of the study have revealed that effective practice of 5S program brings considerable level of improvements in the quality, production, cost optimizations, employee’s morale values and work culture in the manufacturing industry. The industry accrued both tangible and non-tangible benefits through the holistic adoption of 5S principals. 5S principals have been envisioned to further support other quality improvement programs like lean manufacturing initiatives of the organizations. Research limitations/implications The limitation of the study is that this research has been carried out in only manufacturing industry while similar study will be conducted in the service industry also. Originality/value Global competition in the manufacturing sector has provided necessary impetus for manufacturing organizations for affecting continuous improvements in manufacturing performance for achieving sustainability and profitability in the competitive market. 5S implementation is the fundamental tool for the overall achievements in both quantitative and qualitative performance enhancements in the manufacturing as well as service organizations.

Streamlined from the Start

2006 ◽  
Vol 128 (03) ◽  
pp. 30-32 ◽  
Author(s):  
Scott Miller ◽  
James Richmond ◽  
Aron Bowman
Keyword(s):  
Product Development ◽  
Production Process ◽  
Production System ◽  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Development Process ◽  
Toyota Production System ◽  
Lean Product Development ◽  
Innovative Products

This article discusses the importance of lean product development in the manufacturing industry. Lean manufacturing is a concept developed by Toyota more than 30 years ago. It was motivated by the desire to build better and more innovative products with lower costs. The result was the evolution of what is commonly known as the Toyota production system. This system increases efficiency and reduces waste in each area of the production process by eliminating unnecessary efforts and empowering all levels of the workforce. Lean product development is based on the theory of lean manufacturing. The processes focus on simplicity and effectiveness. Lean product development allows for communication between multi-departmental teams, simplifying and keeping the development process moving forward. Using lean product development to manage projects puts accountability on the project owners.

An empirical investigation on lean production system framework in the Indian manufacturing industry

2019 ◽  
Vol 26 (1) ◽  
pp. 296-316 ◽  
Author(s):  
Naga Vamsi Krishna Jasti ◽  
Rambabu Kodali
Keyword(s):  
Production System ◽  
Manufacturing Industry ◽  
Empirical Investigation ◽  
Lean Production ◽  
Cross Sectional Study ◽  
Cross Sectional ◽  
Content Type ◽  
Lean Principles ◽  
Empirical Survey ◽  
High Level

PurposeThe purpose of this paper is to verify the applicability of proposed lean production system (LPS) framework in the Indian manufacturing industry.Design/methodology/approachThe authors conducted a cross-sectional study to collect responses from five major sectors, namely, automobile, process, machines and equipment, electronics and components and textile. They collected 200 responses to perform empirical validation from Indian manufacturing industry. They performed reliability analysis on the proposed framework of LPS in the Indian manufacturing industry.FindingsThe findings revealed that all the elements and sub-elements have a high value in reliability. Subsequently, the study performed principles component analysis on LPS framework. The empirical investigation revealed that the proposed LPS framework has a high level of reliability as well as validity in the Indian manufacturing industry. Hence, the study concluded that the LPS framework is helpful to implement lean principles in a structured manner in any Indian manufacturing industry to achieve excellence in organizational functions.Originality/valueThe authors conducted an empirical survey to verify the applicability of the proposed LPS framework in the Indian manufacturing industry. They observed that many researchers proposed various LPS frameworks, but none of the researchers focused on verifying the proposed frameworks. To overcome, the same limitations, the study verified the proposed framework with the larger sample size.

Application of Pull Concept-based Lean Production System in the Ship Building Industry

2013 ◽  
Vol 29 (03) ◽  
pp. 105-116
Author(s):  
Khairul Hassan ◽  
Hiroyuki Kajiwara
Keyword(s):  
Production System ◽  
Lean Manufacturing ◽  
Simulation Analysis ◽  
Lean Production ◽  
Just In Time ◽  
Optimization Analysis ◽  
Basic Principles ◽  
Pull Production ◽  
Scheduling Method ◽  
Pull Production System

Shipbuilding is a convoluted process. The production system of a shipyard can be illustrated by using the concept of a pull production system. Lean is based on the principle of a pull production system. The shipbuilding process is improved significantly but the lean production system is introduced at very small scales. In a shipyard, different types of wastages such as scraps, overproductions, idle times, etc. are produced, lean is a just-in-time production system that can focus on the elimination of these wastages to ensure lower costs and lower production times and higher quality products as well as better service and delivery. Simulation modeling is used to evaluate the performance of the production system and kanban is a pull-type scheduling method that can be used to simulate the pull production system of a shipyard for the optimization analysis. The goals of this article are to identify the important wastages in a shipyard that can increase production time and cost, to design the production system of a shipyard based on lean philosophy, to derive the basic principles of the lean manufacturing as well as to develop the control mechanism of this production system, the simulation analysis of the production system done by using the lean principle, and to identify the limitations for applying the lean production system in a shipyard production.

scholarly journals Prioritizing Lean Manufacturing Practices in Small to Medium Enterprises by Applying TOPSIS in Fuzzy Environment

2014 ◽  
Vol 903 ◽  
pp. 438-443
Author(s):  
Hamed Tamjid Yamchello ◽  
R. Samin ◽  
Alireza Tamjidyamcholo ◽  
Alireza Rashidi
Keyword(s):  
Decision Making ◽  
Production System ◽  
Lean Manufacturing ◽  
Lean Production ◽  
Multi Criteria Decision Making ◽  
Topsis Method ◽  
Fuzzy Environment ◽  
Lean Practices ◽  
Medium Enterprises

Due to the globalization most of the Small to Medium Enterprises (SMEs) are faced with a lot of pressure to survive. To overcome these pressures, Lean Production System could be very helpful to SMEs. In this research we want to highlight how it can help SMEs, identify limitations to implement lean manufacturing in SMEs and finally prioritize lean practices for implementing in SMEs. For this aim, TOPSIS method in fuzzy environment was applied. Twenty two lean practices which identified by Shah and Ward in 2003 [10] is used as the most suitable lean practices for implementing lean production. Then the barriers of implementing lean production in SMEs identified. An example is provided to illustrate finding of this study. In this study, the barriers of implementing lean production in SMEs were highlighted. It has strived to illustrate the applicability of Multi Criteria Decision Making method in lean production and SMEs. Finally, the result which is the ranked practices of lean production could help managers of SMEs to choose the most suitable practices of lean associated with less risk.

scholarly journals Selection the Basic Lean Manufacturing Techniques in Developing the Model for Industry 4.0 in Kosovo Manufacturing Industry

Proceedings ◽  
2020 ◽  
Vol 63 (1) ◽  
pp. 62
Author(s):  
Fatmir Azemi ◽  
Roberto Lujić ◽  
Goran Šimunović ◽  
Daniel Tokody
Keyword(s):  
Literature Review ◽  
Production System ◽  
Lean Manufacturing ◽  
Industry 4.0 ◽  
Manufacturing Industry ◽  
Manufacturing Industries ◽  
Manufacturing Enterprises ◽  
Lean Tools ◽  
Manufacturing Techniques ◽  
Selection Of

Recently, there have been done numerous investigations related to lean manufacturing techniques. However, very little has been reported about the implementation and selection of lean manufacturing in the Kosovo manufacturing industry. This article presents the application of lean tools through Kosovo manufacturing industries and the selection of the most useful lean techniques for developing a model for an innovative smart Kosovo enterprise which is our initiative in the process of preparing Kosovo enterprises for the new age of industry—Industry 4.0. After several visits through Kosovo enterprises, the literature review has noticed that there is no investigation in the selection and implementation of lean techniques and tools in Kosovo enterprises. The purpose was to understand how Kosovo manufacturing enterprises use lean techniques and which are the most useful techniques. Analyses have been done based on interviews and questionnaires. Seven basic lean techniques are selected based on the response from the questionnaire and representing basic lean tools for developing a model of a production system regarding Industry 4.0.

scholarly journals A REVIEWOF LEANAPPLICATION IN MANUFACTURING ENVIRONMENT: DEFINITIONS AND TERMINOLOGIES

2019 ◽  
Vol 14 (Number 2) ◽  
pp. 28-45
Author(s):  
Azim Azuan Osman ◽  
Abdul Aziz Othman ◽  
Mohd Kamarul Irwan Abdul Rahim
Keyword(s):  
Production System ◽  
Lean Manufacturing ◽  
Lean Production ◽  
Toyota Production System ◽  
Asian Countries ◽  
Manufacturing Environment ◽  
Clear Insight ◽  
The Subject

This articleis a review of definitions and terminologies used in existing literatures related to application of Lean Systemin manufacturing environment. The article is made to provide clear insight and comparisons on various terms used incontemporary academicjournals, booksand published theseson the subject of Lean System.This review realizes that the term Lean Manufacturing was more popular among Malaysian and Asian countries, while Lean Production was mostly used by American scholars. From this review, readers also might learn that Lean System and Toyota Production System are not really the same system due to a missing principle. The presentreview is concluded with visual explanation regarding several major jargons in Lean System.

scholarly journals ASSESSMENT THE UNUSED CAPACITY USING TIME DRIVEN ACTIVITY BASED COSTING IN AUTOMOTIVE MANUFACTURING INDUSTRY

2020 ◽  
Vol 4 (1) ◽  
pp. 82-94
Author(s):  
N.F.A. Ghani ◽  
S.N.A.M. Zaini ◽  
M.Y. Abu
Keyword(s):  
Production Line ◽  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Investment Strategy ◽  
Cost Driver ◽  
Actual Condition ◽  
Activity Based Costing ◽  
Automotive Manufacturing ◽  
Cost Rate ◽  
Capacity Cost

Automotive Manufacturing Industry usually known implementing all six sigma method and lean manufacturing. However, actual practicality in the world of manufacturing, there are a lot of factors contributes that become the challenge to the ideal of lean production line. Not exclude those factors, there is no methods to identify the possible lost cost by the factors. This research is to identify the used-and un-used capacity exist in production line that considering factors affecting the production line at real time. Time-driven activity-based costing (TDABC) is identified as one of the powerful tools to analyze the actual condition of production. Cost-driver rate is defined in Phase 3 where the highest capacity cost rate calculated is RM0.67 per minutes which involving Station 3, Station 5, Station 7 and Station 8. The least capacity cost rate is RM0.33 per minutes recorded by Station 0(Preparation), Station 2 and Station 6. Ten time equations for each station at trim line is developed. During the development of time equation, criticality of Station 7 when it became the only station affected with all thirteen factors listed can be seen as station that needed focus for improvement or target for lean manufacturing. In regards of the relevancy of applying Time-Driven Activity-Based Costing, as a whole, TD-ABC can be used to identify the estimation capacity used either over or under-used. Not only un-used capacity is identified, but result shows Station 0 is over-used by 2932 minutes equals to RM967.56. Therefore, based on the result obtained, station with over-used capacity and several stations with under-used capacity gives a clear overview to the management of the company for better investment strategy.

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.

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