Search Results (18)

In light of the persistent environmental degradation driven by fossil fuels, developing new energy sources is essential for achieving sustainability. The recent surge in electric vehicle adoption has underscored the significance of new energy batteries. However, the supply chains of new energy battery manufacturers face multiple sustainability risks, which impede sustainable practice adoption. To tackle these challenges, leanness philosophy is an effective tool, and Industry 5.0 enhances its efficacy significantly, further mitigating sustainability risks. This study integrates the supply chain, leanness philosophy, and Industry 5.0 by applying quality function deployment. A novel four-phase hybrid MCDM model integrating the fuzzy Delphi method, DEMATEL, AHP, and fuzzy VIKOR, identified five key sustainability risks five core leanness principles, and eight critical Industry 5.0 enablers. By examining a Chinese new energy battery manufacturer as a case study, the findings aim to assist managers and decision-makers in mitigating sustainability risks within their supply chains. Full article

Background: Against the backdrop of the transformation and upgrading of the manufacturing industry, lean manufacturing has emerged as a systematic and advanced production paradigm that has deeply permeated the entire value chain of enterprises. Objective: However, there is a lack of systematic and effective lean technology paradigms in aspects such as lean practice processes and improving manufacturing process efficiency. Moreover, a comprehensive analysis of the current status and development strategies of lean technologies in discrete manufacturing enterprises has yet to be conducted to address issues such as the fragmentation of lean technology applications and the ambiguity of implementation strategies in discrete manufacturing enterprises. Methods: This paper conducts an extensive review of the literature on lean technologies and transformation methods in discrete manufacturing enterprises. A multi-stage data analysis approach (including data identification, screening, eligibility assessment, classification, and comprehensive analysis) is utilized to analyze 369 highly relevant documents. Results: The main contributions of this study are as follows: (1) A comprehensive review of existing lean manufacturing technologies and methods is provided, classifying, comparing, and summarizing the current status of lean technology and strategy applications, and delineating nine categories of lean technology application directions. (2) A “5P” theoretical framework (Philosophy, Process, People, Problem-solving, and Product) is proposed, redefining a lean technology framework that covers the value streams of discrete manufacturing. (3) Future application trends of lean technologies in discrete manufacturing are summarized and predicted, and an implementation strategy for lean technologies tailored to small and medium-sized discrete manufacturing enterprises, along with six lean technology development strategies, are proposed. The results indicate that many enterprises have derived diversified methods based on their own circumstances, which compensate for the deficiencies of the original lean models. Discussion and Conclusions: This paper organizes these methods to serve as a reference for future research on the lean technology system. The proposed strategies include formulating lean transformation strategies for discrete manufacturing enterprises, enhancing proactive lean capabilities, adapting to passive lean factors, and creating value for the enterprises’ reasonable lean needs from three levels: strategic philosophy, objective principles, and tool technologies. This research will play a guiding role in promoting the coordinated development of lean implementation and achieving high-quality development in discrete manufacturing enterprises. Full article

The food industry at the global and local levels is increasingly exposed to severe challenges and disruptions because of rising consumer demands, and rigorous and strict local and international regulations related to food safety and environmental concerns, all of which necessitate the adoption of proven and recognized management philosophies and sustainable practices to run the manufacturing process. Although the food manufacturing industry has adopted total quality management, lean manufacturing practices, and other management philosophies, more efforts are still needed to enhance sustainable performance. The purpose of this study is to explore the integrated impact of TQM and lean manufacturing on the sustainability performance of the food manufacturing industry in Saudi Arabia. Moreover, it investigates the causal relationship between TQM and sustainability performance as well as the direct relationship between TQM and lean manufacturing. The survey questionnaire is used as the primary instrument for collecting data from food manufacturing organizations. Based on the literature review, a theoretical framework is built to hypothesize relationships between the constructs. A structural equation modeling and artificial neural network (SEM-ANN) combined approach is used to analyze the results. The findings of the present study show that TQM and lean manufacturing have a positive impact on sustainability performance. The study also identifies the list of valid constructs for total quality management and lean manufacturing, with a high impact of sustainability performance dimensions. Full article

Total quality management (TQM) is a strategic philosophy that has adopted kaizen activities which drives the business to carry out activities effectively to yield the best desired output, hence, a profitable organization. The kaizen philosophy acts as a catalyst in productivity rate and integrated management systems (IMS) which results in drastic improvements. When the nonconformity arises within the process, the accuracy of the problem solving determines quality of preventive action, therefore the preventive action should be accompanied by the opportunity of improvement from the raised nonconformance. This research seeks to add more knowledge and upgrade technology of problem-solving models relating to the integrated management systems by examining various troubleshooting models for problem solving and preventive action related to quality nonconformances, safety incidents and engineering breakdowns. Hence, the aim of this research is for troubleshooting model technique enhancement for issues related to process engineering, quality management systems and occupational health and safety by creating a model which analyses kaizen projects from the corrective and preventive action analysis of nonconformances. The proposed troubleshooting model was developed using lean techniques and risk rating tools; it was then applied to the case study company for simulation and the outcomes resulted in the closure of nonconformances and continual improvement of future projects. The proposed model is more advantageous to the manufacturing industries seeking to improve their Corrective Action and Preventive Action (CAPA) systems. Full article

Lean Manufacturing has become, in recent years, one of the most important philosophies for improving production and organizational systems. The literature shows that Hesitant Fuzzy Linguistic Terms Sets (HFLTSs) are highly capable of manipulating the uncertainty that the judgments made by evaluators carry and that they are subject to their perception, especially when used in combination with multicriteria decision making (MCDM) for the measurement of indicators in this type of system, as well as their general performance. However, it is still of interest to researchers to develop techniques and instruments that facilitate the measurement of the results obtained after applying this philosophy in organizations. This article proposes a model for the evaluation of the Lean Manufacturing performance through the Analytic Hierarchy Process (AHP) and Dimensional Analysis (DA) using HFLTSs. The results obtained show that the proposed model is a solid tool for the evaluation of Lean Manufacturing systems from a different perspective and that it can be integrated into the issuance of evaluations in a better way by considering human subjectivity. At the same time, it offers a strategy to create priorities in the action plans that Lean system managers propose after evaluating. However, it is important to apply the proposed model to multiple organizations and analyze the results obtained to maximize its benefits. Full article

Manufacturing companies are always looking for ways to outperform their competitors. They are constantly trying to improve their efficiency and reduce costs. One method that improves efficiency and maximises the availability of production equipment is total productive maintenance (TPM), which is a lean optimisation philosophy tool that focuses on the optimisation of maintenance. Although TPM is known for improving maintenance, there are many obstacles to its successful implementation. Failure to properly implement TPM can result in additional costs and lost time, and it can have a negative impact on employees. For these reasons, a survey was prepared and conducted among several companies, each involved in a different field of work and having a different number of employees. The main findings of this research are the key factors that can negatively impact the implementation of TPM and lean tools in general, as well as suggestions for improvements that can ensure their successful implementation and sustainability. An analysis was conducted based on the size of each company as well as the job roles within them. The study covers issues that may arise during the implementation of TPM and other lean tools at all levels of the hierarchy in an enterprise and provides guidance on how to manage situations that may prevent the successful application of TPM. Full article

The furniture manufacturing sector faces intricate challenges in pioneering sustainable supply chains, particularly with lean and sustainable supplier selection. This study focused on integrating key performance indicators (KPIs) associated with lean philosophy and sustainability into multi-criteria decision-making (MCDM) methodologies. The study methodically evaluated 18 criteria spanning economic, environmental, and social dimensions to discern supplier suitability in both leanness and sustainability realms. Through the ENTROPY method, weights were systematically assigned to these criteria. Subsequently, Fuzzy ARAS and Fuzzy TOPSIS methods were adeptly employed to comparatively assess supplier options. Noteworthy findings included the paramount importance of the distance to the customer and labor practices in supplier selection. The quality level, however, carried the least weight, mainly due to comparable performance scores among alternatives. Consistently, Fuzzy ARAS and Fuzzy TOPSIS results converged to pinpoint Supplier 2 as the optimal choice, reflecting its superior K_i and CC_i metrics. Central to this research was the introduction of a structured and holistic framework for lean and sustainable supplier selection, a significant leap forward that promises to be an invaluable asset for practitioners and scholars in the furniture industry, supply chain management, multi-criteria decision-making, and policymaking. Full article

Both the Lean philosophy and occupational safety and health have been widely studied, although this has usually been carried out independently. However, the correlation between Lean and occupational safety and health in the industrial context is still underexplored. Indeed, Lean tools can be applied to ensure the best safety environment for workers in each kind of manufacturing process, and this deserves to be studied. The study described here aims to understand the influence of each of a set of four Lean tools used in an industrial context with a strong manual labor component, seeking to determine the influence of each of these Lean tools on the increase in safety obtained through their application. For this purpose, four Lean tools that are quite commonly applied are selected, taking into account previously presented work that pointed to the positive influence of the application of each of these tools on worker safety: total productive maintenance system, Gemba walk, visual management and Yokoten. This study aims to apply these Lean tools and to analyze their impact on productivity, and then, on the safety of a company selected as a target in order to validate the concept. For this purpose, a new tool is created. In the first instance, the tool analyzes the current state of the productive process and the safety level through the study of the risk levels detected in the plant. In terms of productivity results, a reduction between 7% and 12% in cycle time is achieved in four areas of the plant. The feedback from employees showed increased satisfaction with the processes’ simplification. To conclude, a 50% reduction in the number of work accidents per month is observed as a result of the implementation of Lean tools. The influence of the selected Lean tools on increasing both productivity and safety is clear, and our results prove the selection of tools to be largely adequate. Full article

Lean philosophy has shown successful results in the manufacturing industry since the eighties regarding efficiency, reducing cost and errors. However, the philosophy originated in the private sector, where the work rules are defined by business owners within the framework of some regulation. In the public sector, however, the picture is different. The way of working and carrying out operations and projects is directly defined by regulation, where the owner’s role—as in the private world—is embodied by the entire political system. This article aims to take a comprehensive look at the academic literature on how Lean has been applied in the public sector (LIPS) from a bibliometric perspective and then delve deeper into the concept of lean construction in the public sector (LCPS) through a systematic review. The results give a complete picture of the research in LIPS, revealing that research directions focus on implementing Lean, how it works in the public sector and the human factors involved in its practice and digitalization. Moreover, the advantages and challenges of LCPS have been presented, where again, the human factor is the central concern of researchers. Full article

Recent research asserts that Industry 4.0 technologies have positively impacted Lean Manufacturing and sustainable performance. Although the combined impact of Industry 4.0 and Lean Manufacturing on sustainable performance has been scientifically studied, no study has shown how Lean duration moderates the relationship between Industry 4.0 and Lean Manufacturing in US manufacturing firms. This research aims to close this gap by evaluating whether Lean duration moderates the association between Industry 4.0 and Lean Manufacturing, which in turn affects sustainability performance. The Structural Equation Modeling (SEM) method was used to formulate and examine proposed relationships. The study used data collected from 126 managers who worked in 65 different manufacturing organizations. The data demonstrated a moderating effect of Lean duration on the relationship between Industry 4.0 and Lean Manufacturing and a significant and direct effect of Lean Manufacturing on sustainable performance. However, Industry 4.0 had a positive indirect effect on sustainable performance through the moderating effect of Lean Manufacturing and a negative direct impact on sustainable performance. The study’s findings add to the body of knowledge on the impact of Industry 4.0 on the Lean Manufacturing philosophy by identifying Lean duration as a moderator of this relationship. Theoretically, this research empirically validated the association between Lean duration, Industry 4.0, Lean Manufacturing, and sustainable performance in US Manufacturing organizations. The results showed that industry practitioners should consider the effect of Lean duration when adopting and managing Industry 4.0 technologies for better sustainable performance. Full article

Inventory leanness requires that firms minimize inventory mistreatment and misuse. A firm performance deteriorates because of high inventory misuse, and because of such an issue, the effect on the firm’s credit rating can also be seen. This study examines the effect of inventory leanness on firms’ credit ratings. It aims to create an understanding of the relationship between inventory leanness and the firm’s financial performance and provides insight into the credit rating system of Pakistan. We analyze secondary Pakistan data between 2008 and 2017. Among the sixty firms on Pakistan Stock Exchange that are rated by PACRA, only thirty-eight have complete data available on their respective websites. By using panel data analysis, the results indicate that inventory leanness and credit ratings are positively related. In an added analysis, we evaluate the financial performance in the context of credit rating by using control variables (size, leverage, and capital intensity ratio) and dummy variables (loss and subordinate debt). Our results are consistent with earlier studies. Full article

Currently, lean construction has become very important, with lean manufacturing, a philosophy of production that in the most basic sense refers to the elimination of waste and tries to eliminate anything that does not add value to the product or service, emerging as a Japanese business pattern. The aim of this study was to determine the lean production knowledge among employees in building inspection organizations. To measure the level of awareness in construction inspection institutions, which are the leading entities in the construction sector, and the level of awareness on this issue, a survey was conducted through face-to-face meetings with engineering employees residing in Adana province. The results were converted into datasets in the appropriate Microsoft Excel format. With these datasets, the reliability level of the survey was measured using the SPSS program, and the data were analyzed using WEKA software. The study used association rule learning, a data mining method. According to the results, the number of employees who knew the definition of lean production was less than half, at 47%, while the number of those who knew about the concept of lean construction was 44%. The results obtained according to three different class labels were statistically interpreted, and it was determined that the employees lacked knowledge and sufficient awareness about the subject. Full article

In this study we explored the challenges involved in Lean Transformation and implementation in the manufacturing sector. Using survey data from 50 North American manufacturing organizations, we examined the challenges involved in implementing and sustaining Lean Manufacturing (LM) principles and practices in production processes. The fuzzy analytic hierarchy process (FAHP) and the fuzzy analytic network process (FANP) were used to rank the considerable challenges observed in these organizations. We concluded that the need for a change in organizational culture was the major barrier to Lean implementation. It is challenging to sustain Lean without a culture shift and a clear direction set by the organization’s leadership team. The originality of the paper relates to prioritizing the cultural aspects of organizations as a major barrier to LM implementation. Other challenges encountered during Lean implementation in the manufacturing industries were related to management support, technical knowledge, and employee resistance to change. Early identification of these challenges enables companies to question their capabilities before implementing the Lean philosophy. In this study we used results obtained from 50 manufacturing companies in North America, representing a subset of manufacturing organizations. As a result, it must be interpreted based on the data acquisition method and the study’s sample size. Full article

This work analyzes the current situation of engineering education in India, especially technical universities characterized by low-quality infrastructure, inflexible curricula, and poor teaching resources including faculty, usually resulting in low student learning and very low graduate placement rates, and identifies the root causes of these problems, summarizes the methodologies adapted by previous researchers in the lean area, and applies the lean manufacturing philosophy to engineering education. This paper applies a value stream map to analyze the current state of engineering education. This technique identifies eight wastes and is given in form of a current state diagram. A future state diagram is presented that recommends solutions to eliminate these wastes. These recommendations make learning processes responsive to needs and provide long-lasting value to students. Overall, it is beneficial in developing a policy for engineering education. Full article

This paper investigates the barriers that hinder the implementation of lean manufacturing in wood and furniture industries as the adoption of this philosophy in such industries is not promising especially in emerging economies. To this end, a comprehensive review of the literature was performed to identify the barriers and develop a conceptual model. Next, structural equation modeling is employed to examine the model using the collected data from 131 wood and furniture companies. The findings revealed a synergetic effect between three key factors—culture and human attitude, knowledge, and resources—which play a crucial role in implementing lean. The analyses indicated the reasons of companies refused or not ready to implement lean on knowledge and culture and human attitudinal issues, particularly in companies that have limited resources. It is believed that resource issues are an obstacle to lean implementation, but not as important as knowledge and culture and human attitudinal issues. Sufficient knowledge is needed to deploy lean practices as well as changes in culture and human attitude. Investigating the relationships between these three key barriers is a contribution that this study intends to become a forward step for promoting lean manufacturing among under-studied industries. This paper also proposes that through adopting the activities for lean implementation, small and medium enterprises can experience and quantify the positive impacts of lean practices. Government agencies, universities, and professional bodies can support such enterprises in this transition through targeted interventions that address the barriers presented. Full article