Search Results (30)

The main thrust of the study is the need to cut down the time taken for mold changes in plastic injection molding which is fundamental to the productivity and efficiency of the process. The research encompasses Lean Manufacturing, DMAIC, and SMED which are improved using fuzzy logic and AI for rapid changeover optimization on the NEGRI BOSSI 650 machine. A decrease in downtime by 65% and an improvement in the Process Cycle Efficiency by 46.8% followed the identification of bottlenecks, externalizing tasks, and streamlining workflows. AI-driven analysis could make on-the-fly adjustments, which would ensure that resources are better allocated, and thus sustainable performance is maintained. The findings highlight how integrating Lean methods with advanced technologies enhances operational agility and competitiveness, offering a scalable model for continuous improvement in industrial settings. Full article

This paper aims to enhance operational efficiency in the labor-intensive production of composite wind turbine blades, which are critical components of renewable energy systems. The study was conducted at a wind energy facility in Türkiye, integrating the Single-Minute Exchange of Die (SMED) methodology with a Multi-Mode Resource-Constrained Project Scheduling Problem (MRCPSP) model to reduce production cycle time and optimize labor utilization. An operational time analysis was used to identify and classify non-value-adding activities. SMED principles were then adapted to the fixed-position manufacturing environment, enabling the conversion of internal setup activities into external ones and facilitating task parallelization. These improvements significantly increased productivity and labor efficiency. Subsequently, a scheduling model was developed to optimize the sequence of operations while accounting for activity precedence and resource constraints. As a result, the proposed approach reduced cycle time by 28.6% and increased average labor utilization from 68% to 87%. Scenario analyses confirmed the robustness of the model under varying levels of workforce availability. The findings demonstrate that integrating lean manufacturing techniques with optimization-based scheduling can yield substantial efficiency gains without requiring major capital investment. Moreover, the proposed approach offers practical insights into workforce planning and production scheduling in renewable energy manufacturing environments. Full article

Using microemulsions (µEs) as preservation media for cells was pursued in the 1990s; however, the difficulty in formulating biocompatible µEs and keeping unacclimatized cells alive for more than three days hindered developments in this area. This work explores the use of fully dilutable self-microemulsifying delivery systems (SMEDS) formulated with lecithin (Le) and polyglycerol-10-caprylate (PG10C) at a ratio of 2/5. This surfactant blend was mixed with ethyl oleate (EOL) at a ratio of 60 surfactant/40 EOL to produce a D60 dilution line. This D60 SMEDS was diluted with 0.9% w/v NaCl solution to produce lecithin-linker µEs (LLMs). The properties of the resulting LLMs were predicted using the hydrophilic–lipophilic-difference (HLD) and net-average curvature (NAC) model, indicating that LLMs with aqueous content from 5% to 60% are bicontinuous, confirmed via viscosity and conductivity. The largest yeast activity and viability obtained with LLMs were achieved with 30% aqueous content, resulting from the balance between having enough water for the effective transport of metabolites, enough SMEDS to contribute nutrients and lipids, and a low enough water to limit the partition of PG10C that, when present in the aqueous phase, inhibited yeast activity. For SMEDS, its low water activity ensured that the yeast remained dormant, keeping them alive for at least 10 weeks. Full article

Cognitive radio vehicle ad hoc networks (CR-VANETs) can utilize spectrum resources flexibly and efficiently and mitigate the conflict between limited spectrum resources and the ever-increasing demand for vehicular communication services. However, in CR-VANETs, the mobility characteristics of vehicles as well as the dynamic topology changes and frequent disruptions of links can lead to large end-to-end delays. To address this issue, we propose the social-based minimum end-to-end delay routing (SMED) algorithm, which leverages the social attributes of both primary and secondary users to reduce end-to-end delay and packet loss. We analyze the influencing factors of vehicle communication in urban road segments and at intersections, formulate the end-to-end delay minimization problem as a nonlinear integer programming problem, and utilize two sub-algorithms to solve this problem. Simulation results show that, compared to the intersection delay-aware routing algorithm (IDRA) and the expected path duration maximization routing algorithm (EPDMR), our method demonstrates significant improvements in both end-to-end delay and packet loss rate. Specifically, the SMED routing algorithm achieved an average reduction of 11.7% in end-to-end delay compared to EPDMR and 25.0% compared to IDRA. Additionally, it lowered the packet loss rate by 24.9% on average compared to EPDMR and 32.5% compared to IDRA. Full article

Due to the context of market competitiveness and the economic and financial crisis, companies need to optimize their production systems, tracking the raw material from the suppliers until the final product arrives to the consumer. The Lean philosophy assumes a relevant role for today’s industries through its concepts and tools, enabling optimization, increasing revenues, and having the principle of not expropriating the environment. This article aims to analyse the level of maturity reached by industries in Luanda regarding the practices and tools of the Lean philosophy. A Lean graphic model was built, measured by the Lean Enterprise Self-Assessment Tool (LESAT) maturity model through qualitative and quantitative research focusing on the statistics of 87 circumscribed industries at Viana Industrial Development Pole in the Economic Special Zone of Luanda region, Angola. Initially was conducted an analysis to see whether Lean practices and tools were used: 5S, OKJust-In-Time, Kanban, Bottleneck Analysis, Jidoka, Kaizen, Poka-Yoke, SMED, Gemba, Heijunka, Value Stream Mapping, Hoshin Kanri, and Andon. The next steps were to analyse the following: customer value analysis; value chain analysis; analysis of the use of the pulled production system; and analysis of the use of the continuous production flow analysis of continuous improvement. The result shows these industries using the Lean philosophy at a very low level of maturity. Only the 5S tool was known and used. The JIT, Kanban, and Bottleneck Analysis were moderately used. Only 50% of Lean practices were used. Full article

Objectives: The objective of this study was to analyse and detail surgical process improvement activities that achieve the highest economic impact. Methods: Over 4 years, a team of technicians and healthcare professionals implemented a set of Lean surgical process improvement projects at Vall d’Hebron University Hospital (VHUH), Barcelona, Spain. Methods employed in the study are common in manufacturing environments and include reducing waiting and changeover time (SMED), reducing first time through, pull, and continuous flow. Projects based on these methods now form part of the daily routine in the surgical process. The economic impact on the hospital’s surgical activity budget was analysed. Results: Process improvements have led to annual operational savings of over EUR 8.5 million. These improvements include better patient flow, better management of information between healthcare professionals, and improved logistic circuits. Conclusions: The current cultural shift towards process management in large hospitals implies shifting towards results-based healthcare, patient-perceived value (VBHC), and value-added payment. A Lean project implementation process requires long-term stability. The reason a considerable number of projects fail to complete process improvement projects is the difficulty involved in establishing the project and improving management routines. Few studies in the literature have investigated the economic impact of implementing Lean management a posteriori, and even fewer have examined actual cases. In this real case study, changes to surgical block management were initiated from stage zero. After being carefully thought through and designed, changes were carried out and subsequently analysed. Full article

The business world is becoming more competitive. Therefore, it is crucial to increase the flexibility of production by decreasing the time used in the processes of preparing the production lines for new items’ production, reducing changeover and setup times. This paper presents a case study where the main goal is to reduce the setup time of welding robots. Single Minute Exchange of Die (SMED) was implemented, using other tools such as the Spaghetti Diagram, ERCS Analysis (Eliminate, Rearrange, Combine, Simplify), Gemba Walk, Standardized Work, Flowcharts, and Pareto Diagram. The setup time decreased by 36% in the welding robots studied, decreasing the motions by 43% during the changeover process and reducing the time from the categories: “transportation”, “main”, “other”, and “waiting”. In addition to SMED implementation, this study offers an integrated study of several Lean tools and Quality tools to achieve the maximum reduction of changeover and setup times. Full article

One of the key postulates of the modern automotive industry is the increase in production efficiency while minimizing costs. In the opinion of experts from the automotive industry, meeting this condition may be the first stage on the way to preventing waste generation and implementing a circular economy model. The article presents a case study of issues related to the lean manufacturing methodology in terms of the impact of shortening the changeover time of the assembly line on the overall production efficiency. The presented considerations focus on the optimization of the production process using the SMED (Single Minute Exchange of Die) technique of a selected spare part. From the point of view of the Lean Manufacturing concept, the main goal of the SMED technique is to increase the flexibility of responding to changing customer needs by shortening the changeover times and faster responses to changing orders. The article describes the stages of implementing the SMED method and its impact on the increase in the OEE (Overall Equipment Efficiency) index, which allows for the percentage recognition of the degree of machine park utilization, which is one of the key factors for assessing energy efficiency. In addition, the benefits that have been achieved by using this method in terms of time and economy have been presented. The theoretical aspects related to the method used were supplemented with its practical implementation in order to improve the changeovers in a manufacturing company in the automotive industry. Based on the obtained test results, an analysis of the effectiveness of the measures taken to reduce the changeover time was carried out. The use of the SMED methodology contributed to a significant reduction in changeover time—by as much as 291.4 s. The burden on operators was significantly reduced—the total time and number of operations performed by them (both internal and external) was reduced. Operator paths have also been shortened using simple procedures such as changing the layout of the lines and modifying the changeover tool trolleys and tool locking system at the stations. The presented research may be helpful in answering the question whether the implementation of the SMED idea may be the key to effective resource management and, at a later stage, to the implementation of the circular economy model. In addition, the research results can find their practical application among both manufacturers of spare parts and the vehicles themselves, considering introducing process changes on their production lines in order to increase production efficiency and implementing the idea of industrial sustainability. Full article

European manufacturing companies are currently in a very difficult situation. On the one hand, they have to strive for sustainable development. On the other hand, they have to face problems related to the geopolitical situation and the pursuit of cleaner production (including restrictive regulations on emissions). A significant increase in electricity prices means that companies have to take steps to use electricity rationally without reducing the level of production or incurring other additional costs. In this study, attention was paid to the influence of quality tools (QTs) in production process (PP) management on increasing energy efficiency (EE). Based on the literature review, it was found that the most frequently described QTs, i.e., SMED, TPM, Six Sigma, SPC, FMEA, 5S, or Poka-Yoke, used to improve PP did not take into account their impact on the EE of the enterprises. Therefore, the main purpose of this study was to examine this correlation and show that QTs can be helpful in shaping the energy management system (EMS). Achieving the research goal was possible thanks to surveys carried out among manufacturing companies. Using statistical tests, the existence of a statistically significant correlation was proved between QTs and EMS elements. Full article

We have studied the effect of two glucocorticoid hormones: hydrocortisone and its synthetic analogue methylprednisolone on the regeneration activity of head and tail blastema of the Girardia tigrina planarian. The regeneration activity was studied in head and tail blastema formed after resection by means of lifetime computer morphometry and immunohistochemical labeling of neoblasts. The search for orthologous proteins—glucocorticoid receptors (hydrocortisone) was performed using the SmedGD database of the Schmidtea mediterranea planarian. The results indicate that both hormones influence the recovery rate of the regenerating head and tail blastema. The worms with regenerating tail blastema have less sensitivity to the hormones’ treatment compared to the ones with regenerating head blastema. Hydrocortisone at a high concentration (10⁻³ M) suppressed the regeneration rate, while stimulating it at lower concentrations (10⁻⁴–10⁻⁶ M). The same concentrations of methylprednisolone inhibited the regeneration of head blastema, but did not affect the tail blastema regeneration. The two hormones acted differently: while hydrocortisone stimulated the proliferation of neoblasts in the periwound region, methylprednisolone reduced the mitotic activity, mainly on the tail zone furthest from the wound surface. We suggest that exogenous glucocorticoids can influence endogenous mechanisms of hormone-dependent regeneration. Full article

Background: Exploring the impact of combining Industry 4.0 technologies and Lean Manufacturing tools on organizational performance has been a popular topic in recent years. Design/Methodology/Approach: We propose a novel Smart and Sustainable Manufacturing System (SSMS) to provide management insights related to social impact, economic performance, and environmental impact. Some tools called Dynamic Lean 4.0 tools, such as Sustainable Value Steam Mapping (VSM), Extended Single Minute Exchange of Die (SMED), and Digital Poka-Yoke, are presented as outputs of synergistic relationships that optimize production processes. Originality/Research gap: There are few studies on the application of SSMS. This work presents a case study, aiming to fill this gap. A case study of vacuum degassing equipment fabrication is presented to demonstrate the improvement of utilizing the Define-Measure-Analyze-Improve-Control (DMAIC) method with Digital Poka-Yoke. Key statistical results: The implementation of this project increased the process capability index, Cpk, from 1.278 to 2. Practical Implications: It was concluded that the company successfully implemented a smart and sustainable manufacturing system, and created a safer working environment and new job opportunities, while increasing production yield from 99.44% to 100%, improving worker utilization, and directly saving NT$68,000. Limitations of the investigation: This paper is the use of a single case study. More applications of Dynamic Lean 4.0 tools in SSMS should be explored. Full article

Due to the automotive industry’s strict demands, customers submit constant production pressure, leading to the adoption of new methodologies, techniques, and management ideas. The goal is always to minimise losses and waste. These demands also affect the maintenance department, which has to keep the balance between machines’ availability for production and ensuring that the machines’ proper running conditions translate into excellent-quality products. Thus, continuous improvement and correct management of maintenance activities are crucial for a company to maintain effective production, without defects, breakdowns, and accidents. Nevertheless, some maintenance activities should also prevent the degradation of equipment conditions in order to produce high-quality products. This paper presents an improvement of maintenance activities conducted on equipment that produces large tires. The main problems and technical difficulties of Machine Tolerance Check (MTC) activities are explored by analysing existing documents, internal knowledge, and changes to working methods. We discuss the implementation of the SMED (Single-Minute Exchange of Die) methodology in calibration procedures, as this method is commonly applied to machines’ setups to reduce downtime. At the end of the study, a 31% decrease in the duration of machine tolerance check activities was achieved, which led to a significant increase in the equipment’s availability. Full article

Single-minute exchange of dies (SMED) is one of the most significant lean tools which reduces the required time for setup operations. The consideration of appropriate ergonomic interferences during the SMED implementation improves working conditions, productivity, and flexibility. The SMED literature has an opportunity for expansion with ergonomic assessment. Moreover, ergonomic assessment studies have various limitations in terms of a broad hierarchy of ergonomic factors and their weighting. Therefore, this study enriches the literature by providing the ergonomic assessment of the setup process through integrating multi-criteria decision-making (MCDM) into SMED. In this context, a wide hierarchy of ergonomic risk factors is compiled for ergonomic assessment. The Interval Valued Pythagorean Fuzzy Analytic Hierarchy Process (IVPF-AHP) method is used to determine the weights of factors. Then, Fuzzy Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) is used to prioritize setup tasks in terms of ergonomic factors by using the Interval Valued Pythagorean Fuzzy Sets (IVPFSs). The proposed model was validated by applying it to a real-life manufacturing system in the white goods supplier industry. The application results justify the proposed model with a setup time reduction of 58% and an ergonomic improvement of 19%. Full article

Levofloxacin is considered an alternative treatment option of Stenotrophomonas maltophilia infections to trimethoprim/sulfamethoxazole. The fluoroquinolone resistance in S. maltophilia is usually caused by an overproduction of efflux pumps. In this study, the contribution of efflux systems to levofloxacin resistance in S. maltophilia clinical isolates was demonstrated using phenotypic (minimal inhibitory concentrations, MICs, of antibiotics determination ± efflux pump inhibitors, EPIs) and molecular (real-time polymerase-chain-reaction and sequencing) methods. Previously, the occurrence of genes encoding ten efflux pumps was shown in 94 studied isolates. Additionally, 44/94 isolates demonstrated reduction in susceptibility to levofloxacin. Only 5 of 13 isolates (with ≥4-fold reduction in levofloxacin MIC) in the presence of EPIs showed an increased susceptibility to levofloxacin and other antibiotics. The overexpression of smeD and smeV genes (in five and one isolate, respectively) of 5 tested efflux pump operons was demonstrated. Sequencing analysis revealed 20–35 nucleotide mutations in local regulatory genes such as smeT and smeRv. However, mutations leading to an amino acid change were shown only in smeT (Arg123Lys, Asp182Glu, Asp204Glu) for one isolate and in smeRv (Gly266Ser) for the other isolate. Our data indicate that the overproduction of the SmeVWX efflux system, unlike SmeDEF, plays a significant role in the levofloxacin resistance. Full article

Operations management is a key aspect in any manufacturing business. Optimising the management of manufacturing operations allows improvement of the productivity and efficiency of industrial activities. To achieve this, reducing waste from manufacturing processes and, therefore, implementing lean-manufacturing principles, is key. This article presents a case study to reduce waste in changeover processes at a ready-meal manufacturer based in South Yorkshire, UK. We identified a large number of activities as part of the changeover process. We applied the Single Minute Exchange of Dies (SMED) methodology to reduce and, whenever possible, eliminate changeover, and line hopping to further optimise changeover. After implementing improvement measures, changeover time was reduced by nearly 30%, OEE was increased to over 70%, and labour costs were reduced by 10%. This shows how lean principles can aid in implementing more effective and economically sustainable manufacturing operations. Full article