Prioritization and ranking of lean practices: a case study

PurposeThe paper aims to identify, prioritize and rank lean practices in the context of an Indian automotive component manufacturing organization using interpretive ranking process (IRP) and interpretive structural modeling (ISM) approaches.Design/methodology/approachLean practices are identified from the literature. Then, two hierarchical models were are developed using two distinct modeling approaches – ISM and IRP with expert opinions from an Indian automotive component manufacturing organization to analyze the contextual relationships among the various lean practices and to prioritize and rank them with respect to performance dimensions.FindingsIn the study, the hierarchical structural models are developed using ISM and IRP approaches for an Indian automotive component manufacturing organization. In ISM-based modeling, lean practices can be categorized into five levels. Top priority should be given to the motivators followed by value chain, system/technology and organization centric practices. IRP model shows the dominance relationship among the various lean practices with respect to performance dimensions.Practical implicationsThe models are constructed from the organizational standpoint to evaluate their impact to the implementation of lean manufacturing. The study leverages the organizations to prioritize limited resources as per the hierarchy. Managers get the inter-linkages and ranking of various lean practices, which leads to a better perspective for the effective implementation of lean. The structural models also assist management to assign proper roles to employees/departments for effective lean implementation.Originality/valueThere is hardly any structural model of lean practices in the literature for clustering, prioritizing and ranking of lean practices. The study fills this gap and develops the hierarchical models of lean practices through IRP and ISM approaches for an Indian automotive component manufacturing organization. The results from both approaches are compared for illustrating the benefits of one over the other.

Energy and Carbon Emission Efficiency Prediction: Applications in Future Transport Manufacturing

The long-term impact of high-energy consumption in the manufacturing sector results in adverse environmental effects. Energy consumption and carbon emission prediction in the production environment is an essential requirement to mitigate climate change. The aim of this paper is to evaluate, model, construct, and validate the electricity generated data errors of an automotive component manufacturing company in South Africa for prediction of future transport manufacturing energy consumption and carbon emissions. The energy consumption and carbon emission data of an automotive component manufacturing company were explored for decision making, using data from 2016 to 2018 for prediction of future transport manufacturing energy consumption. The result is an ARIMA model with regression-correlated error fittings in the generalized least squares estimation of future forecast values for five years. The result is validated with RSS, showing an improvement of 89.61% in AR and 99.1% in MA when combined and an RMSE value of 449.8932 at a confidence level of 95%. This paper proposes a model for efficient prediction of energy consumption and carbon emissions for better decision making and utilize appropriate precautions to improve eco-friendly operation.

An Inspection and Classification System for Automotive Component Remanufacturing Industry Based on Ensemble Learning

This paper presents an automated inspection and classification system for automotive component remanufacturing industry, based on ensemble learning. The system is based on different stages allowing to classify the components as good, rectifiable or rejection according to the manufacturer criteria. A study of two deep learning-based models’ performance when used individually and when using an ensemble of them is carried out, obtaining an improvement of 7% in accuracy in the ensemble. The results of the test set demonstrate the successful performance of the system in terms of component classification.