Search Results (368)

Machining Nomex honeycomb structures presents a major challenge due to their thin-walled architecture, orthotropic behavior, and sensitivity to adhesion and delamination. This study develops a three-dimensional numerical model using Abaqus/Explicit to analyze ultrasonic vibration-assisted milling in longitudinal and longitudinal-torsional modes. The model incorporates orthotropic behavior with progressive damage based on Tsai-Wu and experimental friction calibration to accurately reproduce tribological conditions. A parametric analysis examines the effect of vibration mode, amplitude (5–25 µm), frequency (21–22.5 kHz), cutting width, and tool geometry on stresses, bond wear, and material buildup. An optimal coefficient of friction ensures excellent simulation–experiment agreement. Compared to conventional milling, the longitudinal-torsional configuration reduces cutting forces by up to 50%, while frequency optimization allows for gains of 40 to 60%. Hybrid vibration coupling establishes intermittent contact and oscillatory micro-shearing, limiting adhesion and build-up. Thus, longitudinal-torsional assistance improves tribological stability, tool life and wall integrity, offering a validated digital strategy to optimize ultrasonic milling of composite honeycomb structures. Full article

This study examines how lean manufacturing practices are adopted in Singapore’s SME precision and electronics manufacturing industry. Its main goal is to assess the extent of lean manufacturing method adoption and the challenges involved. The study analyzed 36 responses from 150 surveys distributed online. The results show that about 50% of manufacturers find it difficult to implement lean manufacturing practices. Our research reveals that most SMEs face significant challenges when applying lean manufacturing techniques. The findings identify barriers such as a lack of experience, skills, and knowledge, which significantly slow progress. Additionally, the study emphasizes that management support is vital for successful lean implementation. Key factors include employee training, goal alignment, and the creation of a supportive environment. While tools and external expertise are helpful, internal resources and organizational culture are considered more critical. Full article

Lean production philosophy and sustainability approach have become a critical framework for efficiency improvement, waste reduction, and promoting sustainable manufacturing practices. In the age of artificial intelligence (AI), there is a synergy, which has now found new dimensions, data-driven decision-making, predictive analytics, and operational agility. AI technologies promise to transform industrial processes by converging lean production and sustainability principles, a synergy explored in this paper. AI APIs enable the use of AI to improve resource utilization, reduce environmental pressure, and maintain economic growth inherent to all business sectors while also fostering social accountability. In this study, a robust regression model is employed to study the role of AI in moderating the lean practices and sustainability outcomes relationship, using a sample of 528 manufacturing firms. The results show that the contribution of AI technologies to economic, ecological, and social sustainability is effectively multiplied by that of lean production. This research offers a framework to help practitioners and policymakers optimize production systems in line with Sustainable Development Goals. Finally, the study delivers actionable recommendations for navigating skill gaps and cybersecurity risks that were identified. In sum, this paper contributes to the rapidly emerging conversation by providing empirical evidence on AI’s moderating role in the lean–sustainability relationship and offering a strategic framework for practitioners. Full article

This study investigates the application of the SMED (Single-Minute Exchange of Die) methodology to improve operational efficiency and support energy- and resource-efficient manufacturing systems. The research is based on a case study conducted in an automotive company producing electrical harnesses, where SMED was implemented to optimize changeover processes and reduce process-related inefficiencies. The methodological approach follows an AS-IS to TO-BE framework, incorporating direct observation, time measurements, and the classification of activities into internal and external operations. In addition to operational indicators, selected energy- and resource-related aspects such as energy consumption during changeovers, material usage, and waste generation were evaluated based on process observation and indirect estimation. The results indicate a significant reduction in changeover time, along with improvements in machine availability and production flow. Furthermore, the study suggests a reduction in process-related energy consumption and material intensity associated with improved organization and reduced downtime, although these effects are partially indirect. The findings demonstrate that SMED can enhance operational efficiency and indicate its potential to improve energy performance in manufacturing systems, primarily through reduced machine downtime and more stable production flows. However, the results are case-specific, and further research based on direct energy measurements and broader industrial applications is required to confirm their generalizability. Full article

Small and medium-sized enterprises (SMEs) are expected to contribute to sustainable manufacturing, yet they often lack the resources and capabilities needed to adopt advanced automation in a structured and scalable manner. While lean robotics have been widely studied, there is still limited empirical evidence on how their integration can be systematically designed to improve sustainability-oriented performance in SME contexts. This paper examines how a scalable lean robotics system can be conceived and implemented to enhance productivity and resource efficiency in an SME packaging process. We develop a lean robotics design approach that jointly considers lean principles, collaborative industrial robotics, and Industrial Internet of Things (IIoT) monitoring. The approach is applied in a real-world case study of a “Fold Station” robotic cell, where stone paper sheets are destacked, glued, and formed into cylindrical plant protectors. Key performance indicators related to cycle time, material utilization, process stability, and manual workload are measured before and after implementation. The results show a three- to four-fold reduction in preparation time per unit, more efficient use of stone paper and adhesive, and a decrease in repetitive manual handling, thereby contributing to both economic and environmental sustainability. TRIZ (Teoriya Resheniya Izobretatelskikh Zadach, Theory of Inventive Problem Solving) is used to structure the resolution of design contradictions that arise when embedding lean principles into the robotic system and to support its scalable adaptation to different production scenarios. This study advances the understanding of lean robotics for sustainable SME production and derives practical guidelines for designing scalable, resource-efficient robotic cells. Full article

Occupational Health and Safety systems, as well as physical Ergonomics, serve a common goal, which is to eliminate safety-related injuries within production systems. The analysis of potential hazards that could compromise the safety of operations’ employees assists in preventing a high rate of safety-related injuries. Safer processes result in a high output rate and, hence, a profitable business. Focusing on the accuracy of problem solving and failure prediction analysis on new processes could potentially result in zero safety-related injuries, good-quality products, cost reduction, and the elimination of delays within the processes. This research seeks to add more knowledge to the fields of Occupational Health and Safety systems and Total Productive Maintenance by combining lean manufacturing troubleshooting models with Ergonomic analysis, as well as Hazard Identification Risk Analysis, to predict future kaizen projects for businesses. The proposed upgrade to the problem-solving model was developed by evaluating and reviewing the impact of Ergonomic analysis on different production systems. It was found that Ergonomic analysis provides solutions for a more comfortable working environment; hence, the existing troubleshooting model was combined with an Ergonomic exercise. The proposed model is more beneficial to production systems. It could potentially result in zero safety-related injuries, high-quality products, more accurate problem analysis, and more innovation by enabling kaizen projects. The proposed model was applied in the electronics industry, where it resulted in drastic improvements. The old method, which was causing fatigue, was eliminated, and a new machine was designed and prototyped. The new machine assisted the company in this case study in reducing delays, eliminating defects, and reducing costs. Furthermore, the proposed troubleshooting model evaluated an impactful kaizen project, which was the introduction of new technologies that will eliminate the power-up stage. Full article

The socks, hosiery, bodywear (SHB) industry is a critical segment of the textile sector, characterized by high-volume production and rapid delivery requirements, making efficiency and resource optimization essential. A corporate sustainability system is needed to minimize environmental impact, ensure long-term competitiveness, and align operations with global sustainability standards. Thus, this research aims to propose an integrated Corporate Sustainability System (CSS) framework that synergizes Lean Manufacturing (LM), Digital Transformation (DT), and sustainability transition through a methodological triangulation of (1) a narrative review, (2) in-depth expert interviews, and (3) a comprehensive Turkish case study. The proposed framework integrates foundational lean principles such as 5S, TPM, and Value Stream Mapping with Industry 4.0 technologies, including RFID traceability, real-time ERP integration and machine vision systems. Empirical demonstration through the case study reveals that establishing foundational lean maturity is a critical foundation for successful digital adoption. Furthermore, the study demonstrates that transitioning from manual tracking to integrated digital platforms resolves data silos and enhances the transparency of customer revisions and warehouse accuracy. The framework also incorporates human-centric Lean 5.0 improvements, proving that ergonomic interventions such as rail-mounted cable systems are vital for operational sustainability. Ultimately, the CSS provides a scalable model that aligns SHB production with global mandates like the EU Green Deal and CBAM, positioning the sector for long-term competitive advantage in an increasingly eco-conscious global market. Full article

Large-scale composite equipment manufacturing imposes stringent requirements on the lean management of multi-specification fiber prepreg sheet storage, while existing optimization methods suffer from poor process adaptability, insufficient multi-objective collaborative optimization capability, and low space utilization of static layouts. This study constructs a symmetric optimization framework for multi-objective composite sheet storage to address these critical bottlenecks. Specifically, the multi-dimensional process value of fiber sheets is quantified, and the layered storage optimization problem is transformed into a 0–1 knapsack problem with symmetric constraints. An improved Dynamic Programming–Backtracking (DP-BT) material selection algorithm and an adaptive dynamic programming iterative space optimization algorithm are proposed to achieve a symmetric balance of inter-layer space utilization and global optimization. Experimental validation with actual production data of 17 fiber sheet types verifies that the proposed method enables space optimization for specified layer counts to maximize average space utilization, with the rate rising from 79.4% (initial 4-layer layout) to 95.7% (3-layer) and 99.9% (2-layer), and a peak single-layer utilization of 100%. This framework achieves favorable optimization performance in the target production scenario and provides a referenceable symmetric optimization approach for the lean storage management of similar fiber sheet storage scenarios in composite manufacturing. Full article

This study proposes a real-time data-based Digital Value Stream Mapping (Digital VSM) framework that integrates Artificial Intelligence (AI) feature selection and discrete-event simulation validation to enhance production system performance. Unlike conventional VSM approaches that rely on static, manually aggregated data, the proposed framework uses real-time operational data to dynamically quantify Value Added (VA), Non-Value Added (NVA), and Necessary Non-Value Added (NNVA) activities. To improve decision accuracy, an Artificial Neural Network (ANN) combined with Genetic Algorithm (GA) feature selection is employed to identify dominant production variables influencing lead time and line imbalance. Furthermore, Ranked Positional Weight (RPW) optimization results are validated through Tecnomatix Plant Simulation to ensure robustness before physical implementation. The proposed framework was applied to a discrete manufacturing line, resulting in a reduction of total lead time from 8755 s to 6400 s and an increase in process ratio from 33.64% to 45.91%, with line efficiency reaching 91.7%. The findings demonstrate that integrating Digital VSM with AI-driven feature selection and simulation validation transforms Lean analysis from a descriptive tool into a predictive and validated decision-support system suitable for Industry 4.0 environments. Full article

Environmental transparency in food manufacturing requires efficient carbon footprint data collection, yet multi-departmental coordination often creates time-consuming, fragmented processes that impede adoption. This study applies lean office methodologies to optimize carbon footprint assessment processes in food manufacturing. Using a case study approach at a Thai food processing facility, we implemented flow process charts, value stream mapping, eight waste analysis, and ECRS methodology to evaluate the data collection process for strawberry jam production. The baseline assessment documented 142 activities across 12 departments, requiring 17,540 min. The lean interventions included establishing a centralized cross-functional team, developing standardized data collection templates, implementing a unified digital repository system, and consolidating redundant verification procedures. The improved process reduced activities from 142 to 63, decreased the required time from 17,540 to 11,190 min (36.2% reduction), and eliminated 95.8% of non-value-added activities while maintaining regulatory compliance. These efficiency gains enable more frequent environmental assessments and facilitate the broader adoption of carbon footprint measurement within resource-constrained manufacturing contexts. The study demonstrates that lean principles effectively optimize environmental assessment processes themselves, providing a replicable framework adaptable across diverse food manufacturing facilities and product lines while addressing critical adoption barriers including resource constraints and administrative complexity. Full article

This study addresses a critical gap in understanding how Lean Manufacturing (LM) practices, particularly people-centered approaches, can enhance operational performance within the unique industrial context of Saudi Arabia’s Vision 2030 economic transformation. The concept of Lean Manufacturing involves a systematic approach and principles aimed at enhancing efficiency, minimizing inefficiencies, and boosting output in manufacturing operations. While LM principles are well-established globally, their application in Gulf Cooperation Council (GCC) economies remains understudied, particularly regarding the central role of workforce engagement in successful implementation. The main objective of the study is to investigate the implications of LM on the productivity of the industry sector. Specifically, this research examines how the integration of people-centered practices with traditional LM constructs (Just-in-Time, Jidoka, Stability and Standardization) influences operational outcomes in Saudi manufacturing firms. A survey was conducted among specific private and public enterprises to collect data, yielding a 55.8% response rate and 67 valuable responses from a pool of 120 contacted companies. The sample encompassed small, medium, and large enterprises across seven manufacturing sectors. SmartPLS 3 and SPSS were used to assess the structural and measurement models. Common method bias was evaluated using Harman’s single-factor test. The findings demonstrate that implementing the recommended LM structural model significantly enhances operational performance. Notably, people integration exhibited the strongest influence on operational performance (β = 0.361), suggesting that human-centered approaches may be particularly salient in the Saudi context. These findings offer practical guidance for manufacturing firms seeking to align lean initiatives with Vision 2030 objectives. Full article

Additive manufacturing (AM) has been increasingly explored in the construction sector for its potential to improve productivity, reduce waste, and enable design flexibility; however, reported outcomes remain inconsistent, and the relationship between AM and Lean Construction (LC) principles is not yet clearly established. This study addresses this gap through an exploratory, theory-building systematic review of 12 peer-reviewed research articles published between 2021 and 2025, examining AM technologies applied in construction, their associated application contexts, Lean principles, performance indicators, and implementation barriers. A mixed quantitative and qualitative analysis was conducted, combining descriptive bibliometric mapping with thematic synthesis to answer three research questions related to AM applications, Lean impacts, and performance measurement. Given the emerging nature of AM–LC integration and the limited number of eligible studies, the review prioritizes conceptual synthesis over empirical generalization. The results suggest that AM contributes primarily to waste reduction, process efficiency, standardization, and built-in quality when integrated with complementary digital and automation technologies. Nevertheless, significant technical, economic, socio-organizational, and regulatory barriers persist, limiting scalability and performance consistency. Based on the synthesized evidence, the study proposes a conceptual framework that interprets AM adoption as a Lean-oriented production system, where barriers act as system-level constraints and enablers function as Lean improvement mechanisms. This study further conceptualizes AM implementation as a Kaikaku-driven transformation that requires Kaizen-based stabilization through established LC tools. These insights contribute to advancing theoretical understanding of AM–LC integration and guide more effective and systematic implementation in construction projects. Full article

The convergence of Lean manufacturing principles with Industry 4.0 has yielded significant operational improvements, yet the emerging paradigm of Industry 6.0—characterized by antifragile, autonomous, and sustainable systems—demands a fundamental rethinking of existing analytical frameworks. This paper introduces the Industry 6.0 Lean Analytics (I6LA) Framework, a novel meta-theoretical approach that integrates Lean principles with the core concepts of Industry 6.0. By systematically analyzing the limitations of current Lean analytics in the context of Industry 6.0 requirements, we identify critical gaps in areas such as system resilience, AI-driven autonomy, and circular economy integration. The I6LA Framework addresses these gaps through four new theoretical pillars: Antifragile Lean Systems Theory, generative AI-Orchestrated Value Streams, Circular–Regenerative Analytics, and Hyper-Connected Ecosystem Integration. This research provides a new set of mathematical models for measuring antifragility, generative orchestration efficiency, and circularity, offering a comprehensive analytical toolkit for the next generation of manufacturing. The framework’s primary contribution is a paradigm shift from optimizing stable, human-in-the-loop systems to managing dynamic, autonomous ecosystems that thrive on volatility and are regenerative by design. This paper provides both a robust theoretical foundation and practical implementation guidance for organizations navigating the transition to Industry 6.0. Full article

The convergence of Lean manufacturing and Industry 4.0 requires digital infrastructures capable of transforming high-frequency telemetry into actionable insights. However, architectures that integrate near real-time data with closed-loop process control remain scarce, particularly in the food-processing industry. This study proposes a “Lean 4.0” framework based on a six-layer Digital Twin (DT) architecture to digitise waste detection and optimise a medium-scale bakery. The methodology integrates a heterogeneous Industrial Internet of Things (IIoT) network comprising 17 ESP32 (Espressif Systems, Shanghai, China)-based monitoring nodes. Data collection is managed via an edge-centric MQTT–InfluxDB (version 2.7, InfluxData, San Francisco, CA, USA) data pipeline. Furthermore, the analytics layer employs discrete-event simulation in Siemens Plant Simulation (version 2302, Siemens Digital Industries Software, Plano, TX, USA), constraint programming with Google OR-Tools (version 9.8, Google LLC, Mountain View, CA, USA), and machine learning models (Isolation Forest and SARIMA). Multi-month validation in a brownfield bakery, including a 60-day continuous monitoring test, demonstrated that the proposed architecture reduced production cycle time by 24.4% and inter-operational waiting time by 51.2%. Moreover, manual planning time decreased by 87.4% through the use of low-code scheduling interfaces. In addition, state-based control of critical ovens reduced energy consumption by 23.06%. These findings indicate that combining deterministic simulation and combinatorial optimisation with data-driven analytics provides a scalable blueprint for implementing cyber-physical systems in food-processing SMEs. This approach effectively bridges the gap between traditional Lean principles and data-driven smart manufacturing. Full article

As the Industry 5.0 transition unfolds, engineering education must evolve to integrate Lean manufacturing with advanced digital tools and sustainable, human-centred practices. This study presents the design and implementation of a Lean Learning Factory (LLF) that addresses this challenge by combining traditional Lean methods with technologies such as simulation, robotics, and virtual reality in a modular educational environment. At the University Centre Pitești, six hands-on projects were implemented to guide students through key concepts, including production system layout, digital assistance, sustainability, and human–robot collaboration. Through experiential learning, students engage in iterative design, data analysis, and practical validation using real equipment and software platforms. The results indicate that the LLF effectively supports the development of technical, digital, transversal, and human-centred competencies aligned with EUR-ACE^® standards. Students acquire skills in process optimisation, ergonomics, and sustainable production, while also reflecting on the ethical and social implications of automation. The study concludes that the LLF model provides a scalable and adaptable framework for engineering education. It fosters competence-based learning and prepares students for the demands of Industry 5.0. This paper contributes a replicable educational approach that blends Lean efficiency, digital transformation, and human-centred values into a cohesive learning ecosystem. Full article