Development of Lean Assessment Model

IOP Conference Series: Materials Science and Engineering

Lean manufacturing concept is becoming a very important strategy for both academicians and practitioners in the recent times, and Japanese are using this practice for more than a decade. In this present scenario, this paper describes an innovative approach for lean performance evaluation by using fuzzy membership functions before and after implementing lean manufacturing techniques and formulating a model to establish the lean score through the lean attributes by eliminating major losses. It shows a systematic lean performance measurement by producing a final integrated unit less-score.

Purpose – The purpose of this paper is to develop an effective methodology for implementing lean manufacturing strategies and a leanness evaluation metric using continuous performance measurement (CPM). Design/methodology/approach – Based on five lean principles, a systematic lean implementation methodology for manufacturing organizations has been proposed. A simplified leanness evaluation metric consisting of both efficiency and effectiveness attributes of manufacturing performance has been developed for continuous evaluation of lean implementation. A case study to validate the proposed methodology has been conducted and proposed CPM metric has been used to assess the manufacturing leanness. Findings – Proposed methodology is able to systematically identify manufacturing wastes, select appropriate lean tools, identify relevant performance indicators, achieve significant performance improvement and establish lean culture in the organization. Continuous performance measurement matrices in terms of efficiency and effectiveness are proved to be appropriate methods for continuous evaluation of lean performance. Research limitations/implications – Effectiveness of the method developed has been demonstrated by applying it in a real life assembly process. However, more tests/applications will be necessary to generalize the findings. Practical implications – Results show that applying the methods developed, managers can successfully identify and remove manufacturing wastes from their production processes. By improving process efficiency, they can optimize their resource allocations. Manufacturers now have a validated step by step methodology for successfully implementing lean strategies. Originality/value – According to the authors’ best knowledge, this is the first known study that proposed a systematic lean implementation methodology based on lean principles and continuous improvement techniques. Evaluation of performance improvement by lean strategies is a critical issue. This study develops a simplified leanness evaluation metric considering both efficiency and effectiveness attributes and integrates it with the lean implementation methodology.

International Journal of Engineering Management and Economics, 2018

The lean index is a holistic measure of lean performance. Its assessment has been approached using qualitative and quantitative-based methods. While the qualitative based methods are of the self-assessment type, there is no such congruence with quantitative-based ones. This inconsistency can lead to confusion as to which quantitative-based methods should be adopted for specific situations. We attempt to address this issue by applying and comparing some quantitative-based methods within a manufacturing system case. Four methods based on analytical hierarchy process, data envelopment analysis, factor analysis and fuzzy logic, were set apart after a literature review, and applied to the production performance dataset of the case. The methods returned different lean index results thereby providing varied information about system lean performance. Sensitivity tests revealed the data envelopment analysis method to be the most robust.

Journal of Manufacturing Technology Management, 2012

PurposeThe purpose of this paper is to develop a decision support system (DSS) for multi grade fuzzy leanness assessment (MGFLA) (DSS‐MGFLA).Design/methodology/approachThe assessment of leanness gains vital importance. Due to the drawbacks associated with conventional approaches, fuzzy methods are gaining importance. In this context, multi‐grade fuzzy method has been used for leanness assessment. Since the computation is time consuming and error‐prone, a computerized DSS known as DSS‐MGFLA has been developed.FindingsDSS‐MGFLA enables the accurate evaluation of leanness. Besides assessing leanness, DSS also enables the identification of improvement areas. The DSS has been validated in an Indian relays manufacturing organization. Based on the validation, its practical feasibility has been ensured.Research limitations/implicationsDSS‐MGFLA has been validated in a single manufacturing organization for its working feasibility. But the findings could be extended to similar manufacturing o...

South African Journal of Industrial Engineering, 2019

Lean manufacturing is becoming the frontrunner in solving manufacturing-related problems. To sustain the lean journey, assessing lean readiness is the appropriate way to implement it in any industry. In this research, lean readiness is evaluated in a case study industry using a framework model. It consists of two dimensions: the critical success factors, and the barriers. Using force field analysis, the conflicting nature of these dimensions was portrayed. With the help of fuzzy logic, a hierarchical fuzzy system was developed to evaluate lean readiness. The result of this method opens up a new direction for managers to identify lean readiness.

Procedia Computer Science, 2016

In today's competitive business environment, enterprises are facing tremendous pressure of customers' various requests, demand responsiveness, and reducing cost. To meet with such expectations and to enhance the effectiveness of processes of enterprise, lean philosophy is one of the best initiatives. This paper proposes a model that assesses leanness out of four perspectives, three level structures of leanness criterion and twenty eight main criterions.

2014

Lean production has become an integral part of the manufacturing landscape as its link with superior performance and its ability to provide competitive advantage is well accepted among academics and practitioners. Lean production helps producers in overcoming the challenges organizations face through using powerful tools and enablers. However, most companies are faced with restricted resources such as financial and human resources, time, etc., in using these enablers, and are not capable of implementing all these techniques. Therefore, identifying and selecting the most appropriate and efficient tool can be a significant challenge for many companies. Hence, this literature seeks to combine competitive advantages, lean attributes, and lean enablers to determine the most appropriate enablers for improvement of lean attributes. Quality function deployment in fuzzy environment and house of quality matrix are implemented. Throughout the methodology, fuzzy logic is the basis for translating linguistic judgments required for the relationships and correlation matrix to numerical values. Moreover, for final ranking of lean enablers, a multi-criteria decision-making method (PROMETHEE) is adopted. Finally, a case study in automotive industry is presented to illustrate the implementation of the proposed methodology.

Procedia CIRP, 2016

The lean index is the sum of weighted scores of performance variables that describe the lean manufacturing characteristics of a system. Various quantitative lean index models have been advanced for assessing lean manufacturing performance. These models are represented by deterministic variables and do not consider variation in manufacturing systems. In this article variation is modeled in a quantitative fuzzy logic based lean index and compared with traditional deterministic modeling. By simulating the lean index model for a manufacturing case it is found that the latter tend to under or overestimate performance and the former provides a more robust lean assessment.

2015

— In the present global and competitive environment all organizations needs to perform efficiently with higher productivity. For performing efficiently with higher productivity there are so many tools and techniques. Lean is one of them it means using only what is necessary. Lean manufacturing techniques aim to significantly identify waste and eliminate it from the manufacturing processes. The paper is based on a discussion of literature review that shows how the completion of Lean could find importance to the organization processes and contribute for live in competitive environment by fast full benefits i.e. lead time, set-up time, reduction in inventory etc.

Integrated Manufacturing Systems, 2002