A K-Chart based implementation framework to attain lean & agile manufacturing

[EN] Lean manufacturing has always ensured production optimization by eliminating wastes, and its implementation has helped in improving the operational performance of the organization since it eliminates the bottlenecks from the processes, thus making them efficient. In lean scenarios, the focus is on “waste” elimination, but in agile manufacturing, the focus is on the ability of comprehension of changing market dynamics and the resilience. One of the major factors in the combined implementation of lean and agile approaches is inadequate planning, monitoring and lack of awareness regarding changing market trends, and this can be countered by utilizing the effective tool of K-Chart. Through a systematic literature review, the authors establish the requirement of effective planning and monitoring in the implementation of integrated lean and agile approach, concluding that K-Chart is a handy tool to adopt for their effective implementation. The result provides a new vision of lean implementation through K-Chart, whereas it provides clarity to practitioners by presenting a K-chart based implementation framework for achieving favourable results. Being a literature review the research work can be validated through a case study approach in future through a comparative analysis between various implementation techniques and K-Chart.Zaheer, S.; Amjad, M.; Rafique, M.; Khan, M. (2020). A K-Chart based implementation framework to attain lean & agile manufacturing. International Journal of Production Management and Engineering. 8(2):123-135. https://doi.org/10.4995/ijpme.2020.12935OJS12313582Abdullah, M. K., Mohd Suradi, N., Jamaluddin, N., Mokhtar, A. S., Abu Talib, A., & Zainuddin, M. F. (2006). K-chart: a tool for research planning and monitoring. J. of Quality Management And Analysis, 2(1), 123-130.Abdullah, M. K., Suradi, N. R. M., Jamaluddin, N., Mokhtar, S., Talib, A. R. A., & Zainuddin, M. F. 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Approach of the Two-way Influence Between Lean and Green Manufacturing and its Connection to Related Organisational Areas

[EN] Initiatives toward Lean and Green Manufacturing are given mainly due to organisational response to current market’s economic and environmental pressures. This paper, therefore, aims to present a brief discussion based on a literature review of the potential two-way influence between Lean and Green Manufacturing and its role on the main organisational areas with a closer relationship to such approaches, which were observed to be more extensively discussed in the literature. Naturally lean practises seem more likely to deploy into green outcomes, though the other way around can also occur. There is some blur on the factual integration of both themes, as some authors suggest. Notwhithstanding, they certainly present certain synergy. Thereupon, further research is needed to unveil the real ties, overlaps and gaps between these approaches.Salvador, R.; Piekarski, CM.; Francisco, ACD. (2017). 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The prevalent theory of construction is a hindrance for innovation

It is argued that construction innovation is significantly hindered by the prevalent theory of construction, which is implicit and deficient. There are three main mechanisms through which this hindrance is being caused. Firstly, because production theories in general, as well as construction theories specifically, have been implicit, it has not been possible to transfer such radical managerial innovation as mass production or lean production from manufacturing to construction. Direct application of these production templates in construction has been limited due to different context in construction in correspondence to manufacturing. On the other hand, without explicit theories, it has not been possible to access core ideas of concepts and methods of these templates, and to recreate them in construction environment. In consequence, theory and practice of construction has not progressed as in manufacturing. Secondly, it is argued that the underlying, even if implicit, theoretical model of construction is the transformation model of production. There are two first principles in the transformation model. First, the total transformation can be achieved only by realising all parts of it. Thus, we decompose the total transformation into parts, finally into tasks, ensure that all inputs are available and assign these tasks to operatives or workstations. Second, minimising the cost of each task, i.e. each decomposed transformation, minimises the cost of production. It is argued that these principles, in which uncertainty and time are abstracted away, are counterproductive, and lead to myopic control and inflated variability. Practical examples show that these deficiencies and related practical constraints hinder the top-down implementation of innovations. Thirdly, empirical research shows that also bottom-up innovation - systematic learning and problem solving - is hindered by this deficient theory. Thus, the advancement of construction innovation requires that a new, explicit and valid theory of construction is created, and business models and control methods based on it are developed

Lean and green – a systematic review of the state of the art literature

The move towards greener operations and products has forced companies to seek alternatives to balance efficiency gains and environmental friendliness in their operations and products. The exploration of the sequential or simultaneous deployment of lean and green initiatives is the results of this balancing action. However, the lean-green topic is relatively new, and it lacks of a clear and structured research definition. Thus, this paper’s main contribution is the offering of a systematic review of the existing literature on lean and green, aimed at providing guidance on the topic, uncovering gaps and inconsistencies in the literature, and finding new paths for research. The paper identifies and structures, through a concept map, six main research streams that comprise both conceptual and empirical research conducted within the context of various organisational functions and industrial sectors. Important issues for future research are then suggested in the form of research questions. The paper’s aim is to also contribute by stimulating scholars to further study this area in depth, which will lead to a better understanding of the compatibility and impact on organisational performance of lean and green initiatives. It also holds important implications for industrialists, who can develop a deeper and richer knowledge on lean and green to help them formulate more effective strategies for their deployment

Intelligent Products: Shifting the Production Control Logic in Construction (With Lean and BIM)

Production management and control in construction has not been addressed/updated ever since the introduction of Critical Path Method and the Last Planner® system. The predominant outside-in control logic and a fragmented and deep supply chain in construction significantly affect the efficiency over a lifecycle. In a construction project, a large number of organisations interact with the product throughout the process, requiring a significant amount of information handling and synchronisation between these organisations. However, due to the deep supply chains and problems with lack of information integration, the information flow down across the lifecycle poses a significant challenge. This research proposes a product centric system, where the control logic of the production process is embedded within the individual components from the design phase. The solution is enabled by a number of technologies and tools such as Building Information Modelling, Internet of Things, Messaging Systems and within the conceptual process framework of Lean Construction. The vision encompasses the lifecycle of projects from design to construction and maintenance, where the products can interact with the environment and its actors through various stages supporting a variety of actions. The vision and the tools and technologies required to support it are described in this pape

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

Towards a lean model for production management of refurbishment projects, VTT Technology: 94

This is the Stage 3 Report for the ApRemodel project, which aims at improving processes for multi-occupancy retrofit by generating a lean model for project delivery. In this respect, a process-driven approach has been adopted to investigate what can be done to improve the way that retrofits projects are delivered. An initial literature review, focused on the management of refurbishment works, revealed that the research on this matter is scarce. There are plenty of studies related to the broad refurbishment area, however only a small number refer to the way that those construction projects are delivered. According to the literature, construction organisations have predominantly used traditional methods for managing the production of refurbishment projects. The problem is that those tools and techniques are not often appropriate to cope with the complex characteristics inherent to construction projects, especially in the case of refurbishments. Moreover, they have often not been based on a clear theoretical foundation. As a result, numerous types of waste have been identified in refurbishment projects such as waiting time, disruptions in performing tasks on site, rework, among others. This has led to unsatisfactory project performance in terms of low productivity, project delays, and cost overrun. The first step towards better production management in refurbishment projects is recognising the complexity of the sector in order to adopt the correct approach to cope with this specific scenario. In this respect, lean construction is identified as an appropriate way to deal with the complexity and uncertainty inherent in refurbishment projects, given that this management philosophy fully integrates the conversion, flow, and value views. This document builds on the findings from the literature review as well as evidence from case studies. Managerial practices based on lean construction principles have presented successful results in the management of complex projects. Case studies available in the literature report the feasibility and usefulness of this theoretical foundation. Moreover, the evidence from these studies show considerable potential for improving the management of refurbishment works. A list of methods, tools, and techniques are identified. This report may be used by construction refurbishment organisations and housing associations as a starting point for improving the efficiency in managing production of refurbishment projects. To this end, partnerships between industry and academia are strongly recommended. 4 Although the usefulness of lean principles in complex projects is already proved, further work is needed to check what practices are best for the respective refurbishment context, as well as identifying enablers and barriers for practical adoption. Furthermore, additional studies would be also necessary to better understand the extent to which the implementation of lean philosophy might influence performance of refurbishment projects. This report should be seen as work in progress with much more to learn, as detailed research work around the sustainable retrofit process in a lean way is further developed

Applications of lean thinking: a briefing document

This report has been put together by the Health and Care Infrastructure Research and Innovation Centre (HaCIRIC) at the University of Salford for the Department of Health. The need for the report grew out of two main simple questions, o Is Lean applicable in sectors other than manufacturing? o Can the service delivery sector learn from the success of lean in manufacturing and realise the benefits of its implementation?The aim of the report is to list together examples of lean thinking as it is evidenced in the public and private service sector. Following a review of various sources a catalogue of evidence is put together in an organised manner which demonstrates that Lean principles and techniques, when applied rigorously and throughout an entire organization/unit, they can have a positive impact on productivity, cost, quality, and timely delivery of services

Do we need one science of production in healthcare?

The question addressed is: Is there need, in health care, for one consolidated science of production? For responding to this question, the classical science of production is reviewed and the current approaches to production and service in healthcare are analysed as for their evolution and current status. It is found that these current movements are not self-aware of the restrictions deriving from their backgrounds, and of the resultant partiality in their approaches. It is concluded that improvement of healthcare is slowed down by the fragmentation of the related disciplines; thus one consolidated science of production (of healthcare) is needed