LEAN MANUFACTURING TOOLS AND TECHNIQUES IN THE PROCESS INDUSTRY WITH A FOCUS ON STEEL

This research addresses the application of lean manufacturing concepts to the continuous production/ process sector with a focus on the steel industry. The goal of this research is to investigate how lean manufacturing tools can be adapted from the discrete to the continuous manufacturing environment, and to evaluate their benefits on a specific application instance. Although the process and discrete industry share several common characteristics, there are areas where they are very different. Both manufacturing settings have overlap, but at the extreme, each has its unique characteristics. This research attempts to identify commonalities between discrete and continuous manufacturing where lean techniques from the discrete side are directly applicable. The ideas are tested on a large steel manufacturing company (referred to as ABS). Value stream mapping is used to first map the current state and then used to identify sources of waste and to identify lean tools to try to eliminate this waste. The future state map is then developed for a system with lean tools applied to it. To quantify the benefits gained from using lean tools and techniques in the value stream mapping, a detailed simulation model is developed for ABS and a designed experiment is used to analyze the outputs of the simulation model for different lean configurations. Generalizations of the results are also provided

The Remote Site Doctrine in Alaska

In recent years, software development has been evolving around an Agile way of working to optimize software development processes. Simultaneously in other industries, the Leanconcept have been adopted and used to make manufacturing and production of services more efficient. Software development companies has now started to realize that in order to become competitive in software delivery they need to optimize the entire end-to-end process and not only improve the development phase. Thus, an increased interest for Lean thinking has appeared in the industry. Applying Lean successfully in a software development context is not an easy task. This since Lean is developed for and by the manufacturing industry its content is also dependent on the characteristics of this context. Thus, it is not applicable to other contexts without being adjusted. Though, literature argues that when the content of Lean is properly adjusted to nature of the relevant context it can contribute with the same benefits as in manufacturing. However, the literature lack in studies on how Lean can be successfully applied in nonmanufacturing contexts. This study aims to contribute to this knowledge gap by adjusting and applying Lean tools in software development context in order to make the end-to-end processmore time- and resource-efficient. This will be made through a case study at a software development department at a Swedish Information and Communications Technology (ICT) Company. This department develops software components that work as building blocks of the product sold to the end customer. More specifically, these components contribute with functionality that enables communications between the nodes in a network. The review of the existing body of knowledge together with an analysis of the company specific problems indicates that the most sufficient tool to apply in this case study Lean implementation is Value Stream Mapping (VSM). Hence, the study focuses on adjusting the Value Stream Mapping framework to this new context in order to visualize the entire value flow and make improvements aligned with Lean. The adjustments of VSM are underpinned by relevant findings from previous research together with an analysis of the differences between manufacturing Lean and software development Lean. The study shows that it is possible to reasonably adapt and benefit from Value Stream Mapping also in the context of an ICT Company. The outcome of the study is an overview of the current value flow at the company and suggestions on how, where and what improvements can be made. Though, all improvement suggestions evolve around the aim of improving the flow efficiency and eliminating waste by improving the communication, standardization, synchronization, resource allocation and developing proper measurements. The conclusion is that Lean is applicable in the particular software development context with some necessary adjustments made to fit the current way of working and value offering. The usage of Lean tools such as Value Stream Mapping is possible, also here adjustments are a must and the VSM shows that the current state is better in providing a base for improvements than the future state map. This since improvements in this context is not always visualized and captured in the future state map, but the future map contribute to a vision for the valuestream to aim towards. Key words: Lean, Agile, Value Stream Map, Software development, Flow, Waste, Managemen

The Lean Concept in the Food Industry: A Case Study of Contract a Manufacturer

The paper discusses how the lean concept could be applied to a food-manufacturing company. The paper first presents the lean concept and value-stream mapping tools. The empirical section discusses how a case company, operating as a contract manufacturer in the food industry, has applied the lean production concept and tools. In the case study, three analysis tools are examined and the structures of demand chains of different customers are presented. The delivery times will decrease and more flexibility will be needed from the contract manufacturer. The case study shows that much movement is possible toward the lean supply chain and partnership-based cooperation. By implementing the lean concept, food companies can increase customer value through cost reduction or through provision of additional value-enhanced services.Agribusiness,

Enablers and Constraints in Implementing Lean Manufacturing: evidence from Brazilian SMEs

Lean Manufacturing has revolutionized the global manufacturing environment at an unprecedented rate. In scholarly and managerial literature, many works have reported that Lean Manufacturing is a very efficient approach and a straightforward way towards process improvements, in terms of productivity and value adding activities ratio. However, many studies on Lean Manufacturing have highlighted many problems in its implementation. The analysis carried out within the research project is aimed to the factors enabling or constraining the Lean Transformation of a firm’s production system, along with the most relevant tools or practices to be applied. The research methodology used is the so-called “Normative Delphi” with a panel formed by 32 experts coming from 16 Brazilian SMEs. Our results are partially consistent with what has already been discussed in the literature and we found that the most relevant tools/practices are: value stream mapping, 5S methodology, and Kaizen (Gemba walks); the top three enabling factors are: knowledge and sponsorship of senior management, focus on continuous improvement, and employee development fostered by the company; finally, the main critical constraints are: little support from the top management, resistance to change by middle management, and poor or non-qualified Lean training activities

Sustainability-oriented application of value stream mapping: a review and classification

Notwithstanding the research on refining lean tools for the sake of sustainable development is slowly progressing, sustainability-oriented application of value stream mapping has received undivided attention from practitioners and researchers. Going through the literature highlights that there is a lack of research in integrating and systematizing the available knowledge on this lean tool, which is regarded as a visual process-based method to make sustainable progress over the time-based and green concepts of wastes to also assess and improve the societal sustainability performance of organizations. Hence, this paper has been aimed at presenting the findings of a systematic literature review on value stream mapping from the triple bottom line point of view. It classifies and codes the main studies in the context as well as provides a research agenda with nine recommendations that may advance this under-studied field. To narrow the gap in the current literature, this article also proposes a sustainability indicator set that would considerably contribute to guiding and strengthening the state-of-the-art research on successful implementation of the application. Besides, the findings indicate that more investigations are needed on employing survey and conceptual methodologies, applying comparative and cross-industry perspectives, developing sustainability indicator sets particularly societal metrics, and considering the stakeholders' benefits from adopting sustainability-oriented value stream mapping. The research on the convergence of this sustainability-oriented application and new paradigms such as IR 4.0 and/or Circular Economy should be also strengthened

Therblig-embedded value stream mapping method for lean energy machining

To improve energy efficiency, extensive studies have focused on the cutting parameters optimization in the machining process. Actually, non-cutting activities (NCA) occur frequently during machining and this is a promising way to save energy through optimizing NCA without changing the cutting parameters. However, it is difficult for the existing methods to accurately determine and reduce the energy wastes (EW) in NCA. To fill this gap, a novel Therblig-embedded Value Stream Mapping (TVSM) method is proposed to improve the energy transparency and clearly show and reduce the EW in NCA. The Future-State-Map (FSM) of TVSM can be built by minimizing non-cutting activities and Therbligs. By implementing the FSM, time and energy efficiencies can be improved without decreasing the machining quality, which is consistent with the goal of lean energy machining. The method is validated by a machining case study, the results show that the total energy is reduced by 7.65%, and the time efficiency of the value-added activities is improved by 8.12% , and the energy efficiency of value-added activities and Therbligs are raised by 4.95% and 1.58%, respectively. This approach can be applied to reduce the EW of NCA, to support designers to design high energy efficiency machining processes during process planning

Lean Maintenance Roadmap

AbstractMaintenance shares significant operating costs in an organisation. It is considered as a main pillar of the organisational performance. Lean thinking can be incorporated into maintenance activities through applying its principles and practices. Lean maintenance is a prerequisite for lean manufacturing systems. The exhaustive literature review has been conducted to collect the up-to-date maintenance strategies and activities, lean principles and practices in the lean maintenance process. The scope of this paper includes eight types of waste (non-value added maintenance activities), maintenance value stream mapping and a scheme of lean maintenance practices. The output of this paper is a proposed roadmap to apply lean thinking in a maintenance process

Value Stream Mapping: Case Study in a Water Heater Manufacturer

The value stream mapping is a lean production technique used by Toyota Production System (TPS) to visualize and design flow of information, material and production for analyze non-value added and value added operations. In this paper, the method of value stream mapping (VSM) was revealed by literature investigation and an application in a lean manufacturer firm. It is shown that efforts on effective use of source with prevention of waste source in production and increasing value added (VA) operations. In the first part, value stream mapping technique was explained and literature review presented. Second part includes the application study in the electric water heater line of a manufacturing firm. Value stream maps were drawn and therefore non-value added (NVA) works were determined and they had been eliminated in improved case. And last section of the study showed conclusion of lean implementation