An Integrated Framework to Assess ‘Leanness’ Performance in Distribution Centres

The theory behind lean philosophy is to create more value with less. Effective lean management enables organisations to exceed customer expectations while reducing costs. Despite the fact that numerous practices and approaches are used in the process of implementing lean philosophy and reducing waste within supply chain systems, little effort has been directed into assessing the leanness level of distribution and its impact on overall performance. Given the vital role of distribution units within supply chains, this research aims to develop a comprehensive lean assessment framework that integrates a selected set of statistical, analytical, and mathematical techniques in order to assess the ‘leanness’ level in the distribution business. Due to the limited number of published articles in the area of lean distribution, there are no clear definitions of the underlying factors and practices. Therefore, the primary phase of the proposed framework addresses the identification of lean distribution dimensional structure and practices. The other two phases of the framework discuss the development of a structured model for lean distribution and address the process to find a quantitative lean index for benchmarking lean implementation in distribution centres. Integrating the three phases provides the decision makers with an indicator of performance, subject to applying various lean practices. Incorporating the findings of a survey that sent to 700 distribution businesses in Ireland along with value stream mapping, modelling, simulation, and data envelopment analysis, has given the framework strength in the assessment of leanness. Research outcomes show that lean distribution consists of five key dimensions; workforce management, item replenishment, customers, transportation, and process quality. Lean practices associated with these dimensions are mainly focused on enhancing the communication channels with customers, simplifying the distribution networks structure, people participating in problem solving and a continuous improvement process, and increasing the reliability and efficiency of the distribution operations. The final output of the framework is two key leanness indices; one is set to measure the tactical leanness level, while the second index represents the leanness at the operational level. Both indices can effectively be used in evaluating the lean implementation process and conducting a benchmarking process based on the leanness level

Assessment of Systemic Greenness: A Case Study of Tyre Manufacturing Unit

In this paper, we develop an assessment framework to evaluate the systemic greenness of a tyre manufacturing unit by capturing the interactions between the green practices implemented. By reviewing the existing literature, we propose a stakeholder-based green practices framework comprising of operation strategy practices, process practices, employee practices, regulatory practices, customer practices, competition practices, social practices, and supplier practices. The empirical data on the interactions of green practices between and within stakeholders are collected by conducting a detailed case study of a large radial tyre manufacturing unit in India. We use graph-theoretic approach to incorporate the interactions between different green practices and assess the systemic greenness of the case organisation. Based on the systemic greenness attained, we rank the green practices within stakeholders and also between the stakeholders. We conduct scenario analysis to develop a systemic greenness index and a scale to assist practitioners in evaluating and benchmarking the greenness performance. We also discuss implications for theory and practice along with the inherent limitations

Innovation Ecosystems: A Sustainability Perspective

To be competitive, companies must develop capabilities that allow them to react rapidly to market demands. The innovation methods of the past are not adapted to the turbulence of the modern world. In the last decade, increasing globalization of markets and Industry 4.0 have caused profound changes in the best way to manage the innovation process. This e-book includes a collection of thirteen papers that discuss theoretical approaches, case studies, and surveys focused on issues related to open innovation and its mechanisms

Embedding Sustainability in Lean Six Sigma Efforts

The emphasis on the concept of sustainability in businesses and operations is growing either due to increasing public interest, regulatory pressures, or corporate social responsibility. However, where and how to integrate sustainability needs further development for broadening its applications. Using Lean and Six Sigma (LSS) principles in sustainability studies is becoming popular in research and practice. The common approach in these studies is to identify a sustainability project followed by current state sustainability performance assessment, and then work towards improving sustainability performance using LSS tools. The goal of this study was to develop a model framework to fully embed sustainability into any LSS project building on current practices. The wide coverage of LSS, its effectiveness record, and its overlap with sustainability goals establish the foundation for expanding LSS methodology to include sustainability concepts. The proposed framework is not specific to an industry, but is intended to be applicable to the wide spectrum of projects where LSS can be applied. Examples were provided from manufacturing and construction industries in the study. The existing methodologies are framed to target only sustainability initiatives while the presented framework aims to integrate sustainability into any type of improvement initiative. Furthermore, existing methodologies focus almost solely on environmental and economic sustainability, whereas the presented study includes social dimension too. Both academicians and professionals will benefit from the presented framework as it provides a different perspective than what is found in literature enabling broader applications, together with concrete steps and examples demonstrating its implementation, use, and potential benefits

Exploring the roles of ICT in supporting sustainability practices

The concern about sustainability has arisen due to the overuse of natural resources and the increased use of energy consumption over the last decades. Information communication technologies (ICT) has the potential to address the three main aspects of sustainability (people, planet, profit) and therefore, several organizations have initiated a sustainable development by integrating ICT within their business activities. However, the roles of ICT in supporting sustainability initiatives have only been discussed in a limited number of studies and there is a lack of practical examples that demonstrate how the different roles of ICT are played out in an organization\u27s environment. Therefore, this research aims to explore how ICT can be used by organizations to support sustainability initiatives. In particular, in this research- in-progress paper, we examine how a leading organization deploys Internet-of-Things as an example of an ICT application to support various sustainability initiatives. The study findings enhance the current understanding of how ICT can support sustainability practices of organizations

A causal analysis to investigate low production efficiency in the tyre manufacturing industry in South Africa

The evolution of tyre manufacturing in South Africa went back to the early 1930s and matured technologically, becoming automated in the 1960s. The tyre industry in South Africa is worth approximately R30bn per annum and is one of the major supporting industries for domestic vehicle manufacturers. The local industry manufactures only 11 million tyres but can manufacture 18 million tyres per annum. The tyre industry thus plays a crucial role in South Africa’s economic development. Consumers are opting to buy cheaper imported tyres even though tyres are essential purchases. Therefore, the major tyre manufacturers must compete against an estimated 200 importers of various brands, most from China and Japan. The excess local capacity and increasing volume of imports put the local tyre manufacturers under severe pressure to grow their market share, reduce operational cost and achieve economies of scale. The study’s general objective was to conduct a root cause analysis of South African tyre manufacturers’ underlying issues resulting in low production efficiencies. This study used critical manufacturing principles such as traceability, knowledge of lean principles, lean implementation challenges, Total Quality Management, organisational buy-in, waste and rework and maintenance planning that constitute tools of lean practices. These principles provided an opportunity to adopt efficient manufacturing practices in tyre manufacturing companies and help organisations identify improvement areas. A questionnaire was developed and distributed electronically to 93 respondents employed in the tyre manufacturing industry in South Africa. The study addressed product traceability, investigated the quality measures in place, and examined the influence of the workforce’s attitude and morale on productivity, and determined management’s influence on decision-making. The key findings indicated that traceability, lean implementation challenges and organisational buy-in played a significant role in improving production efficiency. Recommendations were made to management to ensure that they lead by example and enhance these key constructs to foster their growth.Thesis (MBA) -- Faculty of Business and Economic Sciences, Business Administration , 202

A causal analysis to investigate low production efficiency in the tyre manufacturing industry in South Africa

The evolution of tyre manufacturing in South Africa went back to the early 1930s and matured technologically, becoming automated in the 1960s. The tyre industry in South Africa is worth approximately R30bn per annum and is one of the major supporting industries for domestic vehicle manufacturers. The local industry manufactures only 11 million tyres but can manufacture 18 million tyres per annum. The tyre industry thus plays a crucial role in South Africa’s economic development. Consumers are opting to buy cheaper imported tyres even though tyres are essential purchases. Therefore, the major tyre manufacturers must compete against an estimated 200 importers of various brands, most from China and Japan. The excess local capacity and increasing volume of imports put the local tyre manufacturers under severe pressure to grow their market share, reduce operational cost and achieve economies of scale. The study’s general objective was to conduct a root cause analysis of South African tyre manufacturers’ underlying issues resulting in low production efficiencies. This study used critical manufacturing principles such as traceability, knowledge of lean principles, lean implementation challenges, Total Quality Management, organisational buy-in, waste and rework and maintenance planning that constitute tools of lean practices. These principles provided an opportunity to adopt efficient manufacturing practices in tyre manufacturing companies and help organisations identify improvement areas. A questionnaire was developed and distributed electronically to 93 respondents employed in the tyre manufacturing industry in South Africa. The study addressed product traceability, investigated the quality measures in place, and examined the influence of the workforce’s attitude and morale on productivity, and determined management’s influence on decision-making. The key findings indicated that traceability, lean implementation challenges and organisational buy-in played a significant role in improving production efficiency. Recommendations were made to management to ensure that they lead by example and enhance these key constructs to foster their growth.Thesis (MBA) -- Faculty of Business and Economic Sciences, Business Administration , 202

Overall Equipment Effectiveness: Systematic Literature Review and Overview of Different Approaches

Overall equipment effectiveness (OEE) is a key performance indicator used to measure equipment productivity. The purpose of this study is to review and analyze the evolution of OEE, present modifications made over the original model and identify future development areas. This paper presents a systematic literature review; a structured and transparent study is performed by establishing procedures and criteria that must be followed for selecting relevant evidences and addressing research questions effectively. In a general search, 862 articles were obtained; after eliminating duplicates and applying certain inclusion and exclusion criteria, 186 articles were used for this review. This research presents three principal results: (1) The academic interest in this topic has increased over the last five years and the keywords have evolved from being related to maintenance and production, to being related to lean manufacturing and optimization; (2) A list of authors who have developed models based on OEE has been created; and (3) OEE is an emerging topic in areas such as logistics and services. To the best of our knowledge, no comparable review has been published recently. This research serves as a basis for future relevant studies