A lean thinking and simulation-based approach for the improvement of routing operations

Purpose: The improvement of routing operations performance has been of great concern for organisations. This has led to the development of alternative lean-based methods, however the literature research on the applications of lean thinking in the transportation sector is still considered rather limited. Therefore, this paper presents a lean thinking and simulation-based approach to improve the efficiency of warehousing and routing operations. Design/Methodology/Approach: The paper reviews the existing literature in the area of lean transportation and then presents and applies a novel approach to improve the vehicle routing operations of a Mexican firm. The proposed approach suggests the classification of wastes into those relevant to transport operations, their identification through a Transportation Value Stream Mapping (TVSM) study, and the use of the Transportation Overall Vehicle Effectiveness (TOVE) index for the measure of the overall performance of the transport operations. Findings: The results obtained from the case study indicate that the proposed approach is an effective alternative for the improvement of vehicle routing operations as the number of routes decreased from 30 to 22 and the distance travelled by 32%. Similarly, the average number of clients served by each route increased by 23% as well as the TOVE index increased from 6.9% to 19.3%. The TOVE component measures of vehicle performance and operating availability efficiencies also increased significantly while quality issues, in the form of number of customers not served per route, were reduced from 6 to 0. Originality/value: The improvement of routing operations performance has been traditionally addressed through operations research and mathematical modelling approaches. This paper presents an alternative and novel lean thinking and simulation-based approach to improve the efficiency of routing operations

Manufacturing System Lean Improvement Design Using Discrete Event Simulation

Lean manufacturing (LM) has been used widely in the past for the continuous improvement of existing production systems. A Lean Assessment Tool (LAT) is used for assessing the overall performance of lean practices within a system, while a Discrete Event Simulation (DES) can be used for the optimization of such systems operations. Lean improvements are typically suggested after a LAT has been deployed, but validation of such improvements is rarely carried out. In the present article a methodology is presented that uses DES to model lean practices within a manufacturing system. Lean improvement scenarios are then be simulated and investigated prior to implementation, thereby enabling a systematic design of lean improvements

Lean and green in the transport and logistics sector – a case study of simultaneous deployment

© 2016 Informa UK Limited, trading as Taylor & Francis Group. The transport and logistics sector is of vital importance for the stimulation of trade and hence the economic development of nations. However, over the last few years, this sector has taken central stage in the green agenda due to the negative environmental effects derived from its operations. Several disciplines including operations research and sub-areas of supply chain management such as green supply chains, green logistics and reverse logistics have tried to address this problem. However, despite the work undertaken through these disciplines, theoretical or empirical research into the sequential or simultaneous deployment of the lean and green paradigms, particularly, in the road transport and logistics sector is limited. This paper presents a case study where both paradigms have been combined to improve the transport operations of a world leader logistics organisation in the metropolitan area of Monterrey, Mexico. To do this, a systematic methodology and a novel tool called Sustainable Transportation Value Stream Map (STVSM) were proposed. The results obtained from the case study indicate that the concurrent deployment of the green and lean paradigms through such methodology and the STVSM tool is an effective approach to improve both operational efficiency and environmental performance of road transport operations. The paper can be used as a guiding reference for transport and logistics organisations to undertake improvement projects similar to the one presented in this paper. Additionally, this research also intends to stimulate scholarly research into the application of lean and green paradigms in the transport and logistics sector to expand the limited research pursued in this area

Improving road transport operations using lean thinking

This paper documents a case study where the transport operations of a word leading provider of paper-based packaging solutions operating in Bogota, Colombia, were measured and improved using lean concepts, methods and tools. The methodology consisted of: (1) direct observations of the transport operations; (2) collection and analysis of data; (3) creation of a Transportation Value Stream Map (TVSM); (4) measurement of the Transportation Overall Vehicle Effectiveness (TOVE); and (5) proposal of improvement recommendations. The TVSM identified six wastes: waiting, resource utilisation, excess movement, over-production, over-processing and behavioural. The TOVE measure resulted in an efficiency of 54%. The study proposed improvement recommendations based on the results of the TVSM and TOVE.N/

A decision support tool, implemented in a system dynamics model, to improve the effectiveness in the hospital emergency department

The emergency department of a hospital is, among all areas in which lean policies are focused, the one that has received the most attention. The emergency room, in fact, plays a vital role in providing primary care to patients and is also recognized for the contribution it gives to society. The important results in terms of cost savings and improving the flow due to the reduction of the waiting time of the patients, obtained from major international hospitals, were crucial to assess whether it was possible and useful to implement similar improvements in Italy, certainly not without to many problems in the provision of health services. This paper explores what can be improved for the department to be more efficient, using simulation techniques based on dynamic and continuous logics (system dynamics)

Mathematical models for operations management

Purpose – The purpose of the doctoral thesis is to support and to facilitate the introduction of lean concepts, in the industry. Design/methodology/approach – Starting from the operating techniques included in the lean toolbox, a comprehensive set of twelve mathematical models for operations management is developed. Since Lean Thinking encompasses the whole organization, the models cover several processes performed by an organization. In particular there are: (i) three models dealing with logistic issues, (ii) five models concerning manufacturing issues, and (iii) four models concerning Total Predictive Maintenance. Findings – The models extend the capabilities of the classical lean tools by means of advanced mathematical techniques such as: fuzzy logic, multi criteria decision making, multivariate statistic and Markov processes. Practical implications – To assure the possibility to adopt the models in real industrial situations, a great effort has been made to maintain all of them as simple and straightforward as possible. Furthermore, all of them have been designed to be easily implemented in industrial information systems, and have been validated by means of industrial applications of relevance. Originality/value – The twelve models here presented provide practitioners with innovative operating tools, which integrate different techniques and overcomes most of the limits of the classical lean tools

Analysis framework for the interaction between lean construction and building information modelling

Building with Building Information Modelling (BIM) changes design and production processes. But can BIM be used to support process changes designed according to lean production and lean construction principles? To begin to answer this question we provide a conceptual analysis of the interaction of lean construction and BIM for improving construction. This was investigated by compiling a detailed listing of lean construction principles and BIM functionalities which are relevant from this perspective. These were drawn from a detailed literature survey. A research framework for analysis of the interaction between lean and BIM was then compiled. The goal of the framework is to both guide and stimulate research; as such, the approach adopted up to this point is constructive. Ongoing research has identified 55 such interactions, the majority of which show positive synergy between the two

Reduce turnaround time through waste elimination.

According to the NHS Confederation (2012), “It’s not good to be a patient stuck on an ambulance trolley in a corridor, but the patients at risk are the road traffic accidents or heart attacks still waiting for the ambulance service to respond”. Ambulance Turnaround time is a measure of particular interest in the performance of Emergency Medical Systems (EMS). It determines the degree of coordination and communication with the health institutions where each patient will receive his final treatment. Its value is key in the determination of the ambulance capacity of the operations system of an EMS institution. Long turnaround times decreases the availability of ambulances for future services and furthermore, it increases ambulance response times and patient´s health risk. This work is about applying an improvement approach based on Lean Thinking for reducing ambulance turnaround time in the EMS operations of the Red Cross located in metropolitan Monterrey, Mexico. Results of the application are provided.N/

Lean manufacturing adoption in the transport and logistics sector of Thailand - An exploratory study

This paper investigates the adoption status of lean manufacturing (LM) in the transport and logistics sector of Thailand. A survey questionnaire was design, validated and distributed among Thai transport and logistics companies. In total, 120 useable responses were received and analysed using descriptive statistics. The results of the study indicate that the implementation of LM is relatively high, with PDCA, 5S and root cause analysis being the most implemented LM approaches and tools. However, the LM’s implementation was found to be mainly contained within individual departments or improvement projects, rather than being a company’s wide strategy. Main challenges to LM implementation included: organisational structure of companies, misalignment between goals of individuals and their companies, and lack of sustainment of a lean culture. Main benefits were the ability to identify and reduce waste, increased productivity and better organisation of workstations. On the other hand, lack of understanding, knowledge and expertise in LM were the main reasons for not implementing it, plus the use of technology-based tools instead of LM. Non-LM companies showed interest in adopting LM in the future, with JIT, Kaizen and Six Sigma being the most likely to implement. This study is among the very first of its kind. It offers academics, researchers and practitioners interested in LM and/or the transport and logistics sector with some initial evidence of the adoption of LM in this industrial sector of Thailand

Methodology for evaluating layout configurations:material flow point of view

Abstract. The key objective for this study is to create a methodology for evaluating facility layout configurations in the case company. Literature review of the study offers an understanding about different types of layout configurations, value creating and waste, and principles which help developing the value creation with layout design. In addition to the literature review, manufacturing operations of the case company is researched with semi-structured interviews and utilizing data from the information systems of the company. Currently the case company does not have a methodology which utilizes data to support decision making for layout decisions. This study introduces how data created by digital twin about material flow of the case company’s assembly processes can be used for supporting layout decisions. As an outcome of the study a software requirement specification is created for the digital twin. Another outcome of the study is a proposition how the data about the material flow should be used. Outcomes of the study can be utilized when using the digital twin for layout evaluation and also applying the possibilities of the digital twin wider to the organization. What comes to the key principles of the method, outcomes of the study can be applied widely in the situations where developing material flow is a significant factor. However, this kind of digital twin and data created by it can be utilized only in the case company.Materiaalivirtaan perustuva layout : vaihtoehtojen arviointimenetelmä. Tiivistelmä. Työn keskeisimpänä tavoitteena on luoda kohdeyritykselle menetelmä tuotannon layoutvaihtoehtojen vertailemiseen. Menetelmän luomiseksi työssä muodostetaan kirjallisuuskatsauksen avulla käsitys erityyppisistä layout-vaihtoehdoista, arvon luomisesta ja hukasta sekä periaatteista, joita huomioimalla arvonluontia voidaan kehittää layoutin avulla. Kirjallisuuskatsauksen lisäksi työn kohteena olevan yrityksen tuotantoprosesseihin tutustutaan teemahaastattelujen sekä yrityksen järjestelmistä haetun datan avulla. Tällä hetkellä kohdeyrityksellä ei ole käytössä menetelmää, jossa dataa pystyttäisiin käyttämään päätöksenteon tukena layoutia koskevissa päätöksissä. Tässä työssä esitellään, kuinka digitaalisen kaksosen tuottamaa dataa tehtaan kokoonpanoprosessien materiaalivirroista pystytään käyttämään päätöksenteon tukena. Työn tuloksena syntyy vaatimusmäärittely digitaaliselle kaksoselle sekä ehdotus, miten sitä tulisi tulevaisuudessa hyödyntää. Työn tuloksia voidaan käyttää työn kanssa yhtäaikaisesti kehitetyn digitaalisen kaksosen hyödyntämiseen layoutsuunnittelussa, sekä digitaalisen kaksosen luomien mahdollisuuksien laajentamiseen myös muihin käyttötarkoituksiin. Työn tuloksia pystyy menetelmän perusperiaatteiden osalta soveltamaan laajasti tilanteisiin, joissa materiaalivirtojen kehittämisellä on vaikutusta. Kohdeyritykseen kehitettyä digitaalista kaksosta ja sen tuottamaa dataa ei pystytä suoraan hyödyntämään kohdeyrityksen ulkopuolella