Challenges in the transformation to lean production from different manufacturing-process choices: a path-dependent perspective

The implementation of lean production remains popular among industrial companies, and the requirement for individualised steps in its implementation is widely accepted; however, research has not yet considered the different process choices available to the companies. The conclusions drawn from the automotive industry's mass production environment may be misleading, given the different conditions of many other industries. We therefore compare case data from a craft producer with the rich, case-study based literature of mass producer companies that highlight the transformation from mass to lean production. We derive a list of specific challenges a craft producer must approach using a different strategy than a mass producer. This study adds to the lean production theory by demonstrating how different manufacturing process choices influence the lean transformation process and its successful implementation. It provides specific propositions concerning the transformation to lean by considering the different processes of craft and mass production companies. Furthermore, the case study gives an in-depth understanding of the challenges a craft-oriented company faces when becoming lean.     

Applicability of lean production with VSM to the Rioja wine sector

Lean production arose as a step towards a new era in production systems. It is a working philosophy designed to produce better products using fewer resources to obtain greater benefits. It has been applied to a wide variety of sectors different from the original automotive industry, in which it was developed. However, its application to continuous manufacturing processes of continuous products has been less, especially to the wine-production sector. The wine sector differs greatly from the automobile sector in various fundamental aspects, but it also has common fundamental aspects in its production and logistics systems. An important part of this work has consisted in studying the wineries of the Rioja region. This article analyses the applicability of lean production in the La Rioja wine sector and the results that may be obtained from its application, using value stream mapping as the main tool to identify opportunities for improvement. This piece of research shows that most of the production problems in the wine sector can be tackled using a lean production system, making certain adjustments according to the type of production. It shows the main properties of wine production from the lean viewpoint, and it improves the production and logistics systems.     

A time-based quantitative approach for selecting lean strategies for manufacturing organisations

Lean strategies have been developed to eliminate or reduce waste and thus improve operational efficiency in a manufacturing environment. However, in practice, manufacturers encounter difficulties to select appropriate lean strategies within their resource constraints and to quantitatively evaluate the perceived value of manufacturing waste reduction. This paper presents a methodology developed to quantitatively evaluate the contribution of lean strategies selected to reduce manufacturing wastes within the manufacturers’ resource (time) constraints. A mathematical model has been developed for evaluating the perceived value of lean strategies to manufacturing waste reduction and a step-by-step methodology is provided for selecting appropriate lean strategies to improve the manufacturing performance within their resource constraints. A computer program is developed in MATLAB for finding the optimum solution. With the help of a case study, the proposed methodology and developed model has been validated. A ‘lean strategy-wastes’ correlation matrix has been proposed to establish the relationship between the manufacturing wastes and lean strategies. Using the correlation matrix and applying the proposed methodology and developed mathematical model, authors came out with optimised perceived value of reduction of a manufacturer's wastes by implementing appropriate lean strategies within a manufacturer's resources constraints. Results also demonstrate that the perceived value of reduction of manufacturing wastes can significantly be changed based on policies and product strategy taken by a manufacturer. The proposed methodology can also be used in dynamic situations by changing the input in the programme developed in MATLAB. By identifying appropriate lean strategies for specific manufacturing wastes, a manufacturer can better prioritise implementation efforts and resources to maximise the success of implementing lean strategies in their organisation.     

People Pillars: Re‐structuring the Toyota Production System (TPS) House Based on Inadequacies Revealed During the Automotive Recall Crisis

Toyota has long been recognized as a leader in lean manufacturing and production quality through a dedicated practice of continuous process improvements and waste elimination techniques hallmarked within their Toyota Production System (TPS) and the ‘Toyota Way’ principles. Toyota's long list of successes and quality achievements has inspired companies within all industry sectors, not just automotive, to seek application of the coveted TPS into their process models in hopes of achieving the rewards that lean production promises. However, a recent series of automotive recall announcements associated with Toyota quality control have led many industry experts and students to reflect on possible inadequacies of the TPS House model. This article seeks to identify potential structural shortcomings and possible deficiencies of the TPS House in light of the root causes of recall crisis and suggest potential re‐structuring to better achieve continuous improvement. Copyright © 2016 John Wiley & Sons, Ltd.     

Lean versus agile production: flexibility trade-offs within the automotive supply chain

Given the recent dynamics of the automotive industry in the UK, the ability for a firm to be flexible has often taken priority over other performance indicators. Using the notion of distinct business models and trade-offs as our theoretical lens, the purpose of this study was to: (1) Distinguish lean and agile firms based upon production methods; and (2) Compare lean and agile levels of external flexibility (EF) and supply chain flexibility (SCF). Data was obtained from 140 automotive firms in the Midlands (UK) via a survey which was sent by emails. Findings supported the theoretical notion of trade-offs, as firms implementing agile production methods were found to be more flexible in comparison with firms implementing lean production methods. More importantly, the agile firms that possessed high EF levels and SCF levels were predominantly positioned at the lower end of the automotive supply chain, whereas the lean firms were largely found to be operating at the top of the supply chain. First, we provide an innovative way in which lean and agile firms can be conceptualised. Second, as flexibility levels were assessed on actual numerical values, as opposed to using opinion based Likert Scale questions, a methodological contribution is made. Third, as flexibility is in its infancy stage of theoretical development we make an empirical contribution by developing a taxonomy that distinguishes each production concept. Finally, given the supply chain position to where lean and agile firms were found, we invoked a power perspective better understand this phenomenon.     

Method for assessing human resources management practices and organisational learning factors in a company under lean manufacturing implementation

The implementation of lean production systems is deemed essential for companies that wish to obtain high levels of competitiveness. There are several examples in the literature discussing the adoption of lean roadmaps; however, since such maps emphasise technical factors of lean change, the organisational learning (OL) process and human resources management (HRM) practices tend to be neglected. This article presents a method for assessing the impact of HRM practices and OL factors in a company under lean implementation. The method incorporates concepts of HRM and OL into lean implementation roadmaps, enabling a maturity analysis regarding dimensions of OL at different contextualisation levels, and allowing the proposition of improvements in HRM practices. The proposed method is illustrated in a case study from the automotive parts manufacturing sector.     

基于价值流图技术的锁体生产系统优化

以某锁体生产线为实际研究对象,开展了生产线现场调研,收集了大量数据,进行了锁体生产线的价值流分析,明确了该生产线的生产流程,绘制了价值流现状图。在对现行流程中的主要浪费——“过量生产”和“库存”的产生原因进行分析的基础上,基于精益思想设计了锁体生产线价值流的未来状态图,确定了以生产链方式的价值流动生产方式,以看板－超市方式控制生产和库存,并对相关的生产计划、生产线平衡、质量控制、设备等进行了优化和改进。项目实施后生产周期减少928%;库存减少928%。     

Application of interpretive structural modelling for analysis of factors influencing lean remanufacturing practices

The contemporary manufacturing scenario witnesses the adoption of lean remanufacturing concepts in a concerted manner. Lean remanufacturing is a newly evolved manufacturing process concerned with manufacturing and remanufacturing of products to effectively utilise available energy and resources, while reducing wastes in the process and thereby increasing efficiency. The advantages include process streamlining coupled with end-of-life decisions. A structural model needs to be developed to clarify the interrelationships among factors influencing lean remanufacturing practices. In this study, interpretive structural modelling method has been used to develop the structural model depicting interrelationships and most dominant and least dominant factors. Twenty factors are being identified based on expert opinion from 35 Indian automotive component remanufacturing organisations. The identified most dominant factors include a strong top management commitment with proper strategy selection, long-term vision and participation and a strong understanding of the current product and process designs. MICMAC analysis has been conducted to categorise the factors. The inferences based on the study have been derived. The novel aspect of this study is that it presents the development of structural model to identify the most dominant factors influencing the implementation of lean remanufacturing principles.     

Proposition of a model for measuring adherence to lean practices: applied to Turkish automotive part suppliers

The objective of this study is to develop a model for measuring adherence to lean practices for automotive part suppliers and to assess the relationship between the firm performance and the adoption of lean principles. This model has been developed by utilising the lean practices defined in the literature. The proposed model has been successfully applied to a large number of automotive part suppliers, and has been tested for its statistical validity. To test the proposed model, data were obtained from 207 automotive part suppliers by using the Computer-aided Telephone Interview method. Validity and reliability tests of the developed model of leanness are realised through exploratory and confirmatory factor analyses. Correlation analyses are used to examine the relationships between the lean applications and company performance and size. Analysis of Variance (ANOVA) is applied to reveal whether there are differences in the use of lean techniques across different company categories. The study shows that, in general, Turkish automotive part suppliers are performing their internal production in compliance with the lean manufacturing principles. Furthermore, it is found that there is a significant relationship between adaptation of lean principles by the supplier firms and their performance. The proposed model of leanness can be used by companies in the automotive industry to measure their leanness levels.     

Collaborative and lean new product development approach: a case study in the automotive product design

Collaboration between buyer and the supplier has been widely studied in the contemporary research to enhance the efficiency of the product development process. Early involvement of stakeholders in development leads to reduced development time and cost and enhanced quality. The current study presents an approach termed as ‘collaborative and lean’ (C&L) approach to new product development (NPD). It involves application of lean principles in a collaborative environment between an automotive component supplier and the original equipment manufacturer (OEM). The study compares the deployment of two methodologies of development – generic process and the C&L process for developing the same part by a supplier for two different OEMs. Development with one OEM was done using generic process and the other using the C&L process. The study uses value stream mapping of the various phases of the development and attempts to understand the application of the proposed approach in the automotive domain. It highlights the potential of a combined C&L approach in reducing non-value-adding activities, cycle time and effort during NPD. The study attempts to enhance the understanding of NPD in a collaborative environment and explores the possible merits of the proposed approach.     

A simulation-enhanced value stream mapping approach for optimisation of complex production environments

Value stream mapping (VSM) is a widely adopted method for transformation of production environments into a lean operational state. The straightforwardness as well as the completeness, with which processes are analysed and optimised, are key to the success of the method originating from the automotive industry. However, these attributes of the ‘paper and pencil’ approach result in limitations when applying VSM in complex production environments. This research paper targets to overcome these limitations, specifically in production environments involving significant demand variability, complex routing and cost factors which potentially increase with lean implementation. For this purpose, an enhanced VSM method is developed, which utilises discrete event simulation (DES). The method features a feasibility and trade-off analysis which is incorporated into the VSM procedure. A case study covering a process of exhaust gas purification catalyst production is then conducted to test the newly developed method. The VSM project yields a shop floor lead time reduction from 11.4 to 1.4?d. The additional DES feasibility and trade-off analysis determines customer demand fulfilment and quantifies the monetary benefit of the future state. In that way, potential iterative implementation which is inherently oppositional to the lean philosophy is avoided.     

Japanese New-Product Development Techniques

Yasuhiro Monden The Japanese automotive industry has already become a by-word for lean production efficiency. Recently attention has shifted to its new-product development activities, and in particular to the techniques of simultaneous engineering that generate superior performance when contrasted with the traditional linear and sequential approaches. The paper probes the cost management system that underpins the Japanese automotive product-development system, enabling a network of producers and suppliers to work cooperatively and in parallel through successive prototyping stages of the process. The core concept is the iterative development of a 'target cost' for each component of the process.     

Optimal process capability analysis for process design

Conventional process capability analysis is used to measure and control the quality level of a production process in real exercises for on-line quality management. There has been a deficiency in this type of management; namely, the defects which occur in the production process are only passively detected and modified afterwards. Additionally, conventional process capability expression has difficulty distinguishing between alternatives for process selection among possible candidates before process realisation. There is, therefore, considerable motivation for developing a process capability expression which can be used to evaluate alternatives at the beginning of the process design, i.e., off-line application. The conventional C_pm expression is built up by measuring mean deviation and process variances for on-line application. However, if C_pm is used for the process capability analysis for process design, an erroneous C_pm value is found and an inappropriate process design is ended. Thus, the proposed process capability expression revised from the conventional C_pm in consideration of the balance between tolerance cost and quality loss has been developed. This development is the main contribution of this research and, with this development, the appropriate mean and tolerance values can be determined simultaneously prior to the real production process so as to maximise the proposed process capability value. The production is then processed with the pre-determined mean and tolerance values in a real production process. The expectation after process realisation is that the produced responses will be the best of all the alternatives in terms of quality and cost, and that the process capability value obtained after the real production process will be close to the proposed process capability value maximised prior to the real production process.     

A framework for System Excellence assessment of production systems,based on lean thinking,business excellence,and factory physics

This article proposes a production system framework that synthesises lean production, business excellence, and factory physics. The framework, which draws on a deep state-of-the-art understanding, consists of a performance measurement system supporting the achievement of a target condition based on variability and lead time reduction, as well as approaches of continuous improvement. Based on four types of excellence, a System Excellence value is calculated, indicating the distance from a target condition and thus displaying relevant improvement potential. As a key result, the framework proposed provides a contribution to knowledge, as it combines the aforementioned schools of thought, resulting in a holistic framework for action. The measurement system offers a high level of robustness, as it draws on diverse data sources and reflects on the dynamic behaviour over time. It has been successfully implemented in automotive manufacturing plants worldwide, which may suggest considerable practical relevance. Another key result of this research is that through applying the framework, important bottom-line indicators, such as lead time, failure costs, or productivity, could be improved. As the plants are typical automotive industry high-volume plants, it is proposed that the solutions presented offer a suitable standard for this industry and type of plant.     

An AHP-multicriteria suitability evaluation of technological diversification in the automotive industry

This paper advances a methodological framework for analysing the process of technological diversification in the automotive industry and presents a multicriteria procedure, based on the analytic hierarchy process (AHP), to evaluate, in a simple and user-friendly manner, the suitability of technological diversification for any company in the automotive sector. The AHP-multicriteria procedure associated with the initial stage of the methodology and the decision support systems developed to evaluate suitability have been applied to 22 Spanish automotive companies. The multicriteria procedure classifies the companies into three different groups: (i) those that are suitable for diversification; (ii) those for which product development (innovation) or market development (internationalisation) is more appropriate; (iii) those that are not suitable for any diversification process. The true value added in this initial stage of the technological diversification process is not, despite its importance, the final classification of the firms, but the learning procedure derived from the multicriteria analysis and the evaluation of diversification suitability. From this learning procedure, a set of recommendations related to the diversification of the automotive companies is extracted.     

Commercial Viability of Al-Based MMCs in the Automotive Segment

Based on the cost-to-quality ratio evaluation related to automotive applications of discontinuously reinforced aluminum-based composites, R & D efforts, directed toward a further lowering of the cost of composite material, are considered. The results of the study indicate that a viable business concept for applications of discontinuously reinforced metal matrix composites (MMCs) in the automotive segment should be built up on the development of an end user-friendly and preferably one step production technology. This should be capable of producing near net-shaped automotive parts in MMC grade consisting of fine ceramic particles of average particle size around 1 μm or less and keeping the production cost at the current level.     

Application of analytical network process for analysis of product design characteristics of lean remanufacturing system: a case study

The modern manufacturing systems are adopting with lean practices to ensure value addition and waste elimination. Also, product recovery options are found to be vital. Appropriate product design characteristics are identified, and their prioritization is framed as decision-making problem with multiple criteria. Analytical network process is used as solution methodology. The objective of the study is to formulate multi-criteria decision making problem for assessment of lean remanufacturing product design characteristics. The priority order of lean remanufacturing operations is obtained. The study is exemplified with a case conducted with reference to remanufacture of an automotive component. The priority order of criteria is Disassembly > Cleaning > Inspection > Remanufacturing > Reassembly. The inferences desired from the study would facilitate cleaner manufacturing practices. Sensitivity analysis is conducted and practical validity of the method has been tested with an industrial case study.     

Requirements in performance measurement systems of construction projects from the lean production perspective

Performance measurement (PM) generates useful data for process control, facilitates communication between different sectors, and helps to align efforts on the most important aspects of the business. Thus, PM plays a key role in the management of projects and organizations. PM is also important in the implementation of lean production principles and methods, such as reducing the share of nonvalue-adding activities, increasing process transparency, building continuous improvement into the process, and benchmarking. Moreover, the adoption of the lean production philosophy requires changes in PM. Despite its importance, limited studies have been conducted on the use of PM systems for assessing the impact of lean production programs in construction projects. In addition, studies on how lean companies (or projects) use performance measurement and to what extent the indicators adopted reflect the result of actions that have been undertaken are limited. This study proposes a set of requirements in PM systems of construction projects from the perspective of lean production and a taxonomy of performance metrics for lean production systems. Five empirical studies have been carried out on construction companies from South America involved in the implementation of lean production systems. The scope of this investigation is limited to the construction projects as production systems rather than PM at the level of construction organizations.     

Tools and techniques for enabling sustainability through lean initiatives

There has been a paradigm shift in the manufacturing systems. Lean manufacturing is a manufacturing system that is focused on the elimination of wastes thereby facilitating process streamlining and waste reduction. In the recent days, the need for environmental consciousness is very much realized. The environmental waste is regarded as the ninth waste. This article focuses on the exploration of various issues of sustainability using lean initiatives. Also, some of the strategies/techniques that would enable the achievement of sustainability objectives using lean initiatives are presented.     

Criteria for a lean organisation: development of a lean assessment tool

Lean principles have long been recognised as a competitive advantage. Although there are several measures for various aspects of lean production in the literature, there is no comprehensive measure for overall lean implementation in business firms. An appropriate measurement tool is needed to assess the effectiveness and efficiency of the lean implementation throughout the entire organisation. Based on lean research, a comprehensive tool called the leanness assessment tool (LAT) is developed, using both quantitative (directly measurable and objective) and qualitative (perceptions of individuals) approaches to assess lean implementation. The LAT measures leanness using eight quantitative performance dimensions: time effectiveness, quality, process, cost, human resources, delivery, customer and inventory. The LAT also uses five qualitative performance dimensions: quality, process, customer, human resources and delivery, with 51 evaluation items. The fuzzy method allows managers to identify improvement needs in lean implementation, and the use of radar charts allows an immediate, comprehensive view of strong areas and those needing improvement. Practical uses of the LAT are discussed in the conclusion, along with possible limitations.