International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
The Toyota Production System - A Transition from Mass Production to Lean Manu...Nurhazman Abdul Aziz
The Toyota Production System
A Transition from Mass Production to Lean Manufacturing and Supply Chain Management
by Genaro J. Gutiérrez
McCombs School of Business
The University of Texas at Austin
Understanding the Need of Implementation of Lean Techniques in Manufacturing ...ijtsrd
In competitive environment lean manufacturing is necessary in every industry. Lean production is a standard manufacturing mode of the 21st century All the manufacturing industries have put a continuous efforts for its survival in these current world. In order to handle the critical situations manufacturers are trying to implement new and innovative techniques in their manufacturing process. Later on lean was formulated and developed as the solution to the fluctuating and competitive business environment. Due to rapid change in business environment the manufacturing organization are forced to face challenges and complexities in the competition. The concept of lean manufacturing was developed for maximize the resource utilization and minimize the wastes. The main focus of the lean manufacturing is to satisfy customer demands for high quality and low cost. The technique not only identifies the reasons for waste but also helps in its removal through marked principles and guidelines. Lean Manufacturing is an efficient and fast growing approach in the world of competition. Lean manufacturing utilizes a wide range of tools and techniques the choice of tools is based on the requirement. Many parameters contribute success of lean. Organizations which implemented lean manufacturing have higher level of flexibility and competitiveness. However, lean manufacturing provides an environment that is highly conducive to waste minimization. The majority of the study focuses on single aspect of lean element, only very few focuses on more than one aspect of lean elements, but for the successful implementation of lean the organization had to focuses on all the aspects such as Value Stream Mapping VSM , Cellular Manufacturing CM , U line system, Line Balancing, Inventory control, Single Minute Exchange of Dies SMED , Pull System, Kanban, Production Leveling etc., G. K. Kiran Kumar ""Understanding the Need of Implementation of Lean Techniques in Manufacturing Industries: A Review "" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23194.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23194/understanding-the-need-of-implementation-of-lean-techniques-in-manufacturing-industries-a-review-/g-k-kiran-kumar
Implementation of Lean Manufacturing Principles in FoundriesIJMER
It is the general perception that the foundry industries are inherently more efficient and have a relatively less requirement for major improvement activities. Managers and engineers have also been hesitant to implement lean manufacturing tools and techniques to the continuous sector because of typical and identical characteristics that sector. These include costly and special purpose inflexible machines, options of modifications in machines are limited ,long setup times, and the general difficulty in producing in small batches.
Lean manufacturing technology when applied appropriately in a process industry , can help in eliminating waste , enhance the quality of product , attain better and smooth control on operations and thereby reducing the production cost and production time .
Role of IT in Lean Manufacturing: A brief ScenarioIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
Operation management, toyota production systemOmar Hamdan
The success of Toyota Motor Company is due to the unique reduction systems that focus on continuous improvement and just in time management. Toyota has created a decentralised structure that encourages employee participation and team working. Toyota incorporated concepts just as supply chain management and inventory management to create high quality automobiles and gain a competitive edge in the highly competitive global automobile market. Toyota’s success and its lean manufacturing philosophy have been widely studied. The Toyota manufacturing system is centred on achieving a high level of productivity. The company has a unique approach to problem solving and it continuously trains its employees.
The Toyota Production System - A Transition from Mass Production to Lean Manu...Nurhazman Abdul Aziz
The Toyota Production System
A Transition from Mass Production to Lean Manufacturing and Supply Chain Management
by Genaro J. Gutiérrez
McCombs School of Business
The University of Texas at Austin
Understanding the Need of Implementation of Lean Techniques in Manufacturing ...ijtsrd
In competitive environment lean manufacturing is necessary in every industry. Lean production is a standard manufacturing mode of the 21st century All the manufacturing industries have put a continuous efforts for its survival in these current world. In order to handle the critical situations manufacturers are trying to implement new and innovative techniques in their manufacturing process. Later on lean was formulated and developed as the solution to the fluctuating and competitive business environment. Due to rapid change in business environment the manufacturing organization are forced to face challenges and complexities in the competition. The concept of lean manufacturing was developed for maximize the resource utilization and minimize the wastes. The main focus of the lean manufacturing is to satisfy customer demands for high quality and low cost. The technique not only identifies the reasons for waste but also helps in its removal through marked principles and guidelines. Lean Manufacturing is an efficient and fast growing approach in the world of competition. Lean manufacturing utilizes a wide range of tools and techniques the choice of tools is based on the requirement. Many parameters contribute success of lean. Organizations which implemented lean manufacturing have higher level of flexibility and competitiveness. However, lean manufacturing provides an environment that is highly conducive to waste minimization. The majority of the study focuses on single aspect of lean element, only very few focuses on more than one aspect of lean elements, but for the successful implementation of lean the organization had to focuses on all the aspects such as Value Stream Mapping VSM , Cellular Manufacturing CM , U line system, Line Balancing, Inventory control, Single Minute Exchange of Dies SMED , Pull System, Kanban, Production Leveling etc., G. K. Kiran Kumar ""Understanding the Need of Implementation of Lean Techniques in Manufacturing Industries: A Review "" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-3 | Issue-3 , April 2019, URL: https://www.ijtsrd.com/papers/ijtsrd23194.pdf
Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/23194/understanding-the-need-of-implementation-of-lean-techniques-in-manufacturing-industries-a-review-/g-k-kiran-kumar
Implementation of Lean Manufacturing Principles in FoundriesIJMER
It is the general perception that the foundry industries are inherently more efficient and have a relatively less requirement for major improvement activities. Managers and engineers have also been hesitant to implement lean manufacturing tools and techniques to the continuous sector because of typical and identical characteristics that sector. These include costly and special purpose inflexible machines, options of modifications in machines are limited ,long setup times, and the general difficulty in producing in small batches.
Lean manufacturing technology when applied appropriately in a process industry , can help in eliminating waste , enhance the quality of product , attain better and smooth control on operations and thereby reducing the production cost and production time .
Role of IT in Lean Manufacturing: A brief ScenarioIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
Operation management, toyota production systemOmar Hamdan
The success of Toyota Motor Company is due to the unique reduction systems that focus on continuous improvement and just in time management. Toyota has created a decentralised structure that encourages employee participation and team working. Toyota incorporated concepts just as supply chain management and inventory management to create high quality automobiles and gain a competitive edge in the highly competitive global automobile market. Toyota’s success and its lean manufacturing philosophy have been widely studied. The Toyota manufacturing system is centred on achieving a high level of productivity. The company has a unique approach to problem solving and it continuously trains its employees.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Trough External Service Management Improve Quality & ProductivityIJMER
Abstract: The challenges in Small car project, necessitated improvements in quality and productivity,
right from day one of implementation of project. Detailed studies on external management services,
manufacturing process, various departments involved, and procedures followed were done, and
problems in the existing system were identified and solutions were provided. The object of this paper is to
investigate methods of measuring performance. The subject of this paper is the process of implementing
methods to increase productivity. Methods (procedures) of the study. Pattern during the writing of this
work was used by scientist’s articles information about the measurement and implementation of systems
productivity. Since this work was written with the use of different methods and examples, not all of them
before writing the work were known to me, I want to present a certain part to improve the productivity of
some companies in my country.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Trough External Service Management Improve Quality & ProductivityIJMER
Abstract: The challenges in Small car project, necessitated improvements in quality and productivity,
right from day one of implementation of project. Detailed studies on external management services,
manufacturing process, various departments involved, and procedures followed were done, and
problems in the existing system were identified and solutions were provided. The object of this paper is to
investigate methods of measuring performance. The subject of this paper is the process of implementing
methods to increase productivity. Methods (procedures) of the study. Pattern during the writing of this
work was used by scientist’s articles information about the measurement and implementation of systems
productivity. Since this work was written with the use of different methods and examples, not all of them
before writing the work were known to me, I want to present a certain part to improve the productivity of
some companies in my country.
Presentación realizada en el curso "La biblioteca pública en el entorno digital: bibliotecas virtuales", La Antigua Guatemala, del 04 al 08 de abril de 2011.
This paper developed an analytical background to scientific development conducted on the use of
Lean Manufacturing in the industries. Regarding the methodological approach to this research is exploratory and
did a literature review with a sample survey using technological resources search as a tool to perform the search
in this case, the component data bases Journals Portal Coordination and Training of Personnel Higher Level. For
this study bibliometric analysis and the selection of journals were made and the results show that the topic is
Lean Manufacturing on the rise internationally and that is a methodology mentioned in leading journals. The
scientific literature on the topic is not predominantly done by a single magazine or a single industry segment.
The contribution is in identifying the gaps of the segments of the industries with the greatest opportunities for
the application of Lean Thinking so that future studies can deepen effectively is opportunity.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
Lean thinking literature review and suggestions for future researchWorld-Academic Journal
The research provides a literature overview from a timespan of more than 60 years with articles historically and thematically organized about the application of “Lean thinking” (LT) concept and the main research findings through different industries. Lean thinking is an important but yet still under researched aspect of strategic management. By collecting research records from ISI web of knowledge naming directly the lean thinking issue; 34 Web of science records, 10 Medline records and 2 Chinese citation database records were found. Results show that the main focus areas on lean thinking researches are mainly applied in health care industry (with the 48% of the collected records) followed by manufacturing industry (17%), construction (10%), product development (7%), training and education (7%) and supply chain (2%). Other industries (9%) are also starting to apply lean thinking philosophy according to the particularities of their domain. We find research gaps and provide directions for further investigation.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
KAIZEN: A Lean Manufacturing Techniquevivatechijri
Now-a-days the ultimate goal of all industries is to enhance productivity through simplified system
and incremental improvements by applying some modern available techniques. At present, many manufacturing
companies are facing problems such as high quality rejection, high inventories, high lead time, high costs of
production, and inability to cope with customer orders. By implementing and practicing the lean production
system many problems can be solved without employing high-tech and high-touch approaches but by involving
people on the shop floor in Kaizen activities. For continuous improvement in an organization, Japanese
philosophy Kaizen is very popular. Flawless concepts of Kaizen methodology and proper implementation of tools
can lead to a successful kaizen program in a company. Kaizen is one of the powerful tools of lean manufacturing.
Kaizen refers to continuous improvement in performance, cost and quality. Kaizen ensures that manufacturing
processes become leaner and fitter, but eliminate waste (problem) where value is added. The main objective of
this paper is to provide a background on kaizen, present an overview of kaizen concepts that are used to transform
a company into a high performing lean enterprise.
Keys to Succeed in Implementing Total Preventive Maintenance (TPM) and Lean S...IJMTST Journal
Competition is global and it continues to get more intense, with changes in technology, introduction of new and differentiated products and techniques. These changes are faster than what can be implemented. Profits are no longer driven by prices but with costs.[1] Customers have access to just about anything at their finger tips. The expectation like quick response, lower prices, flexible orders and quality products, is increasing every day from the customers. Our OEM’s (Original Equipment Manufacturers) are searching for new methods of doing business and they expect their suppliers, like us to do the same. The challenge in front of us is how we respond effectively to these changing trends in the industry for our survival & growth. Change is the only certainty and the above is very much applicable to any business to achieve and sustain competitive edge. It is evident that organizations, which are innovative and visionary, have successfully implemented the change, realizing its business strategies would lead to their long term survival
GraphSummit Singapore | The Art of the Possible with Graph - Q2 2024Neo4j
Neha Bajwa, Vice President of Product Marketing, Neo4j
Join us as we explore breakthrough innovations enabled by interconnected data and AI. Discover firsthand how organizations use relationships in data to uncover contextual insights and solve our most pressing challenges – from optimizing supply chains, detecting fraud, and improving customer experiences to accelerating drug discoveries.
Pushing the limits of ePRTC: 100ns holdover for 100 daysAdtran
At WSTS 2024, Alon Stern explored the topic of parametric holdover and explained how recent research findings can be implemented in real-world PNT networks to achieve 100 nanoseconds of accuracy for up to 100 days.
A tale of scale & speed: How the US Navy is enabling software delivery from l...sonjaschweigert1
Rapid and secure feature delivery is a goal across every application team and every branch of the DoD. The Navy’s DevSecOps platform, Party Barge, has achieved:
- Reduction in onboarding time from 5 weeks to 1 day
- Improved developer experience and productivity through actionable findings and reduction of false positives
- Maintenance of superior security standards and inherent policy enforcement with Authorization to Operate (ATO)
Development teams can ship efficiently and ensure applications are cyber ready for Navy Authorizing Officials (AOs). In this webinar, Sigma Defense and Anchore will give attendees a look behind the scenes and demo secure pipeline automation and security artifacts that speed up application ATO and time to production.
We will cover:
- How to remove silos in DevSecOps
- How to build efficient development pipeline roles and component templates
- How to deliver security artifacts that matter for ATO’s (SBOMs, vulnerability reports, and policy evidence)
- How to streamline operations with automated policy checks on container images
Enchancing adoption of Open Source Libraries. A case study on Albumentations.AIVladimir Iglovikov, Ph.D.
Presented by Vladimir Iglovikov:
- https://www.linkedin.com/in/iglovikov/
- https://x.com/viglovikov
- https://www.instagram.com/ternaus/
This presentation delves into the journey of Albumentations.ai, a highly successful open-source library for data augmentation.
Created out of a necessity for superior performance in Kaggle competitions, Albumentations has grown to become a widely used tool among data scientists and machine learning practitioners.
This case study covers various aspects, including:
People: The contributors and community that have supported Albumentations.
Metrics: The success indicators such as downloads, daily active users, GitHub stars, and financial contributions.
Challenges: The hurdles in monetizing open-source projects and measuring user engagement.
Development Practices: Best practices for creating, maintaining, and scaling open-source libraries, including code hygiene, CI/CD, and fast iteration.
Community Building: Strategies for making adoption easy, iterating quickly, and fostering a vibrant, engaged community.
Marketing: Both online and offline marketing tactics, focusing on real, impactful interactions and collaborations.
Mental Health: Maintaining balance and not feeling pressured by user demands.
Key insights include the importance of automation, making the adoption process seamless, and leveraging offline interactions for marketing. The presentation also emphasizes the need for continuous small improvements and building a friendly, inclusive community that contributes to the project's growth.
Vladimir Iglovikov brings his extensive experience as a Kaggle Grandmaster, ex-Staff ML Engineer at Lyft, sharing valuable lessons and practical advice for anyone looking to enhance the adoption of their open-source projects.
Explore more about Albumentations and join the community at:
GitHub: https://github.com/albumentations-team/albumentations
Website: https://albumentations.ai/
LinkedIn: https://www.linkedin.com/company/100504475
Twitter: https://x.com/albumentations
Removing Uninteresting Bytes in Software FuzzingAftab Hussain
Imagine a world where software fuzzing, the process of mutating bytes in test seeds to uncover hidden and erroneous program behaviors, becomes faster and more effective. A lot depends on the initial seeds, which can significantly dictate the trajectory of a fuzzing campaign, particularly in terms of how long it takes to uncover interesting behaviour in your code. We introduce DIAR, a technique designed to speedup fuzzing campaigns by pinpointing and eliminating those uninteresting bytes in the seeds. Picture this: instead of wasting valuable resources on meaningless mutations in large, bloated seeds, DIAR removes the unnecessary bytes, streamlining the entire process.
In this work, we equipped AFL, a popular fuzzer, with DIAR and examined two critical Linux libraries -- Libxml's xmllint, a tool for parsing xml documents, and Binutil's readelf, an essential debugging and security analysis command-line tool used to display detailed information about ELF (Executable and Linkable Format). Our preliminary results show that AFL+DIAR does not only discover new paths more quickly but also achieves higher coverage overall. This work thus showcases how starting with lean and optimized seeds can lead to faster, more comprehensive fuzzing campaigns -- and DIAR helps you find such seeds.
- These are slides of the talk given at IEEE International Conference on Software Testing Verification and Validation Workshop, ICSTW 2022.
Sudheer Mechineni, Head of Application Frameworks, Standard Chartered Bank
Discover how Standard Chartered Bank harnessed the power of Neo4j to transform complex data access challenges into a dynamic, scalable graph database solution. This keynote will cover their journey from initial adoption to deploying a fully automated, enterprise-grade causal cluster, highlighting key strategies for modelling organisational changes and ensuring robust disaster recovery. Learn how these innovations have not only enhanced Standard Chartered Bank’s data infrastructure but also positioned them as pioneers in the banking sector’s adoption of graph technology.
20 Comprehensive Checklist of Designing and Developing a WebsitePixlogix Infotech
Dive into the world of Website Designing and Developing with Pixlogix! Looking to create a stunning online presence? Look no further! Our comprehensive checklist covers everything you need to know to craft a website that stands out. From user-friendly design to seamless functionality, we've got you covered. Don't miss out on this invaluable resource! Check out our checklist now at Pixlogix and start your journey towards a captivating online presence today.
Threats to mobile devices are more prevalent and increasing in scope and complexity. Users of mobile devices desire to take full advantage of the features
available on those devices, but many of the features provide convenience and capability but sacrifice security. This best practices guide outlines steps the users can take to better protect personal devices and information.
Observability Concepts EVERY Developer Should Know -- DeveloperWeek Europe.pdfPaige Cruz
Monitoring and observability aren’t traditionally found in software curriculums and many of us cobble this knowledge together from whatever vendor or ecosystem we were first introduced to and whatever is a part of your current company’s observability stack.
While the dev and ops silo continues to crumble….many organizations still relegate monitoring & observability as the purview of ops, infra and SRE teams. This is a mistake - achieving a highly observable system requires collaboration up and down the stack.
I, a former op, would like to extend an invitation to all application developers to join the observability party will share these foundational concepts to build on:
Maruthi Prithivirajan, Head of ASEAN & IN Solution Architecture, Neo4j
Get an inside look at the latest Neo4j innovations that enable relationship-driven intelligence at scale. Learn more about the newest cloud integrations and product enhancements that make Neo4j an essential choice for developers building apps with interconnected data and generative AI.
Essentials of Automations: The Art of Triggers and Actions in FMESafe Software
In this second installment of our Essentials of Automations webinar series, we’ll explore the landscape of triggers and actions, guiding you through the nuances of authoring and adapting workspaces for seamless automations. Gain an understanding of the full spectrum of triggers and actions available in FME, empowering you to enhance your workspaces for efficient automation.
We’ll kick things off by showcasing the most commonly used event-based triggers, introducing you to various automation workflows like manual triggers, schedules, directory watchers, and more. Plus, see how these elements play out in real scenarios.
Whether you’re tweaking your current setup or building from the ground up, this session will arm you with the tools and insights needed to transform your FME usage into a powerhouse of productivity. Join us to discover effective strategies that simplify complex processes, enhancing your productivity and transforming your data management practices with FME. Let’s turn complexity into clarity and make your workspaces work wonders!
Unlock the Future of Search with MongoDB Atlas_ Vector Search Unleashed.pdfMalak Abu Hammad
Discover how MongoDB Atlas and vector search technology can revolutionize your application's search capabilities. This comprehensive presentation covers:
* What is Vector Search?
* Importance and benefits of vector search
* Practical use cases across various industries
* Step-by-step implementation guide
* Live demos with code snippets
* Enhancing LLM capabilities with vector search
* Best practices and optimization strategies
Perfect for developers, AI enthusiasts, and tech leaders. Learn how to leverage MongoDB Atlas to deliver highly relevant, context-aware search results, transforming your data retrieval process. Stay ahead in tech innovation and maximize the potential of your applications.
#MongoDB #VectorSearch #AI #SemanticSearch #TechInnovation #DataScience #LLM #MachineLearning #SearchTechnology
GridMate - End to end testing is a critical piece to ensure quality and avoid...ThomasParaiso2
End to end testing is a critical piece to ensure quality and avoid regressions. In this session, we share our journey building an E2E testing pipeline for GridMate components (LWC and Aura) using Cypress, JSForce, FakerJS…
How to Get CNIC Information System with Paksim Ga.pptxdanishmna97
Pakdata Cf is a groundbreaking system designed to streamline and facilitate access to CNIC information. This innovative platform leverages advanced technology to provide users with efficient and secure access to their CNIC details.
UiPath Test Automation using UiPath Test Suite series, part 6DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 6. In this session, we will cover Test Automation with generative AI and Open AI.
UiPath Test Automation with generative AI and Open AI webinar offers an in-depth exploration of leveraging cutting-edge technologies for test automation within the UiPath platform. Attendees will delve into the integration of generative AI, a test automation solution, with Open AI advanced natural language processing capabilities.
Throughout the session, participants will discover how this synergy empowers testers to automate repetitive tasks, enhance testing accuracy, and expedite the software testing life cycle. Topics covered include the seamless integration process, practical use cases, and the benefits of harnessing AI-driven automation for UiPath testing initiatives. By attending this webinar, testers, and automation professionals can gain valuable insights into harnessing the power of AI to optimize their test automation workflows within the UiPath ecosystem, ultimately driving efficiency and quality in software development processes.
What will you get from this session?
1. Insights into integrating generative AI.
2. Understanding how this integration enhances test automation within the UiPath platform
3. Practical demonstrations
4. Exploration of real-world use cases illustrating the benefits of AI-driven test automation for UiPath
Topics covered:
What is generative AI
Test Automation with generative AI and Open AI.
UiPath integration with generative AI
Speaker:
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
1. Lavlesh Kumar Sharma et al Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 4, Issue 5( Version 2), May 2014, pp.94-101
www.ijera.com 94 | P a g e
An Explanatory Study of Lean Practices in Job Shop Production/
Special Job Production/ Discrete Production/ Batch Shop
Production Industries
Lavlesh Kumar Sharma1
, Ravindra Mohan Saxena2
, Dr. Lokesh Bajpai3
1
Student of M. Tech. (C.I.M.), S. A.T. I. Vidisha (M.P.)
2
Asst. Prof. Department of Mechanical Engineering, S.A.T.I. Vidisha (M.P.) Head of Department of Deptt.
Mechanical Engineering, S.A.T.I. Vidisha (M.P.)
Abstract
In this paper, the study explores the benefits and advantages of Lean Practices or Lean Thinking in Job shop
production/ Special job production/ Discrete production/ Batch shop production industries. The Lean Practices
have been applied more compatible in Job shop production than in the continuous/ mass production because of
several barriers and hurdles in the industrial context that influence the whole processes again and again, this
happens due to the lack of knowledge about the wastes during the production of a variety of jobs or discrete
manufacturing. This paper provides the guidelines to adopt and mentions to become Lean. In variety of
production, it is very difficult to find out all the wastes during the processes from input to desired output, thus
Lean techniques may be most suitable to minimize the wastage, time, inventory and assist to improve quality
and become economical. These wastes may be managed by means of several Lean principles and techniques
available. This paper gives a brief introduction of VSM, in order to recognize the opportunities for the various
lean techniques, VSM is the main tool, especially it is used to observe the wastes and time spoilage through
knowledge management.
Key words: Lean Manufacturing, Value Stream Mapping, Knowledge management, waste, value, flow
I. Introduction
Lean manufacturing or Lean thinking
approach was developed with the publication of the
book “The Machine that changed the world” by the
Womack, Roos and Jones (et al 1990). It is a
reference to the Lean concept pioneered by Toyota.
This book explores the additional to the Japanese
production methods, concepts and studies as
compared to traditional western methods; it also
highlighted the superior performance to be Lean.
Traditional manufacturing systems are built on the
principle of economics of scale. The large fixed costs
of production are depreciation intensive because of
huge capital investments in high volume production.
Due to high volume production there may be higher
wastes. The follow on book Lean thinking: Banish
waste and create wealth in your organization by
Womack and Jones ( et al 1996). As an alternative to
Batch-and-queue, high volume and inflexible
operations, the principle of the Toyota production
system (TPS) have been widely adopted in recent
years even throughout the US. Application of TPS
principles has brought to lean production which
results:
1) Elimination of wastes
2) Smooth work flow across a wide variety of
products
3) High quality output
4) Flexible operation
5) Lower total unit production costs
Lean manufacturing is one of the initiatives
that many major industries ( manufacturing,
fabrication, process, chemical, hospitality, health and
food industries) in the Us as well as rest of the World
have been trying to adopt to remain competitive in an
increasing global market. But if you talking about
people who working in these industries can truly say
that they have idea about Lean? And the reply will be
not many. The focus of Lean approach is on cost
reduction by eliminating Non-value added activities
and many of the tools and techniques of Lean
manufacturing (TPM, JIT, Cellular manufacturing,
Kaizen, production smoothing) have been widely
used in discrete manufacturing. But in the beginning-
the Birth of Lean was in Japan within Toyota in the
1940s. Taiichi Ohno had started work on the TPS in
the 1940s and continued its development into the late
1980s by the advancements in computers which had
allowed mass production to be further enhanced by
the MRP systems. In 1970s Toyota’s own supply
base was also Lean. On the other hand, application of
Lean manufacturing in the continuous process sector
have been far fewer( Abdullah and Rajgopal et al
2003) because such industries are inherently more
sufficient and have a relatively less urgent need for
RESEARCH ARTICLE OPEN ACCESS
2. Lavlesh Kumar Sharma et al Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 4, Issue 5( Version 2), May 2014, pp.94-101
www.ijera.com 95 | P a g e
major improvement activities. However Lean
manufacturing becomes a paramount of all the recent
methods of improvements to the manufacturing
industries, Lean thinking (Womack and Jones, 1996)
always aided us to understand the principles of the
Lean:
1) The identification of value
2) The elimination of Waste
3) The generation of flow.
II. Knowledge Management
For the installation of Lean, basically
required the knowledge transmission in the system
and among the people. Here the knowledge is meant
by the reorganization of the both, the teams
operational and management level. Thus the
knowledge management is handled by the CFT
(Cross Functional Team). A well managed
knowledge transmission is critical to the
sustainability of change.
Wastes: any activity in a process which does not add
value to the customer is called waste. And it may be
necessary part of the processes and sometimes it is
observed that during the production many wastes
always happened, Japanese describe seven wastes
called as TIMWOOD.
Flow: Flow is one of the critical to understand
different wastes as lean point of view. To understand
flow, you need to analyze the concept of value
stream.
Value: Value is related to the customer. The
identification of value is the very initial point to
manage.
III. Literature Survey
As the evolution of lean manufacturing was
started in Japan after World War II, Toyota
Production System (TPS) emphasized on elimination
of wastes and Non-value added (NVA) activities.
TPS’s Chief Engineer Taiishi Ohno developed Lean
Concept in 1940. Womack, Roos, Jones (1990)
studied the implementation of lean manufacturing
practices in the automotive industry on a global scale.
In 1996 Womack and Jones helped us to understand
the principle of lean (value, waste, flow). Further
Womack and Jones (2003) defined 5 lean principles:
Specifying value, identifying the value stream, flow,
Pull system, and perfection. The successful
application of various lean practices has been
documented in a variety of industries, such as
aerospace, computer manufacturing and automotive
assembly (Mac Duffie, Sethuraman, and Fisher 1996;
Laughnin 1995; Houlahan 1994). James- Moore and
Gibbons (1997) determine that the level of lean
manufacturing adoption in the aerospace industry
was lower than expected as a result of high product
mix and low volumes. Previous research has also
identified the management of human resource as
significant issue in the implementation of Lean
(Agraval and Graves 1999; Bambar and Dale 2000;
Nicholas 1999; Yauch and Steudel 2002). Product
designers, process engineers and workers are isolated
functionally, geographically or across organizations,
decentralization of authority become more
challenging,and the ability to effect change through
continuous improvement activities is more difficult.
This can also hinder Kaizen (continuous
improvement) activities, which are foundational to
lean ( Detty and Yingling 2000). Lean production has
now expended and Lean thinking has been applied to
all aspect of the supply chain. Lean thinking to
business process has been well explained by the
Melton (2003 & 2004). JIT is a technique of Lean
was developed through its levels by Fullerton,
Mcwatters and Fawson (2003). TPM, TQM and
Human resource management was well analyzed by
Shah and Ward (2003). There are many other
researchers and practitioner may be reviewed to
identify a complete set of lean practices and existing
research instrument that might be leveraged for the
study.
IV. Background
A Brief overview may assist to explore the
benefit of the lean principles followed by some
Wastes
Transport Inventory
Defects
Over
Processing
Motion
Over
Production
Waiting
Figure: 1
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background information on discrete manufacturing or
Batch shop production where the work was
conducted.
Lean manufacturing and its tools: After
World war II Japanese manufacturers were faced
with vast storage of men, material and money. These
conditions resulted in the birth of lean manufacturing
concept (Taiichi Ohno et al 1994). Japanese
industrial leaders such as Kiichiro Toyoda, Schigeo,
Shingo and Taiichi Ohno responded by devising a
new disciplined process oriented system which is
known as the TPS or Lean manufacturing.
Key tools of lean system may be given as followings:
Kanban: A visual signal to support the flow by
pulling product through the manufacturing process.
Just- In-Time (JIT): A system where customer
requirement is fulfilled by transmitting the demand
from the final assembly of the desired product all the
way to raw material by pulling all the requirements
just when they are required.
Total Preventive Maintenance (TPM): It referred
to the regular equipment observation to detect
anomalies so that the breakdowns may be prevented
by proper monitoring.
5S’s: A visual housekeeping technique developed by
Japanese to maintain working shop floor.
Total Quality Management (TQM): This lean
technique is focused on customer demand for the
continuous improvement by means of Employee
involvement and training, problem solving teams and
statistical analysis.
Cellular Manufacturing: for similar product,
processes are managed into cells which are intended
to arrange easily facilitation of all the processes
within these cells.
SMED (Single Minute Exchange of Dies): A
changeover reduction technique.
Poke yoke: An error-proofing technique.
Setup time reduction: Continuously try to attempt
the setup time reduction on a machine.
Visual control: A method of measuring performance
at the shop floor.
V. Overview of VSM
Value Stream Mapping is a technique to
represent the flow of product manufacturing along
with adequate information. VSM is a collection of all
activities (value added as well as Non-value added)
needed for the conversion of raw material to desired
output and ending with customer. Thus recognizing
Non-value added activities is VSM’s main function.
These activities consider the flow of both material
and associated information within overall supply
chain. The ultimate goal of VSM is to identify all
types of wastes across each step (Rother and Shook et
al 1999). Thus VSM is intended to provide the
opportunity to understand the selection of suitable
Lean technique. For implementing the Lean concepts,
a map provides a blueprint by illustrating how the
flow of material and information should operate.
VSM also helpful to develop the following features:
a) Flow Visualization (to understand the complex
activities)
b) Identify where waste occurs ( to understand the
most suitable lean techniques)
c) Integrated the Lean manufacturing principles (
for having the better solutions)
d) Decide the implementation team (evolution of
forces to be Lean)
e) Relate properly information an physical flows.
Visualizing the flow creates the ability to
understand where, when and how the product flows
associated with its adequate information. Moreover
VSM may be divided into two components big
picture mapping and detailed mapping. Big picture
mapping includes five phases:
a) define customer requirements
b) map information flows
c) map physical flows
d) link physical and information flows
e) Complete the map by using icons and symbols.
And include a time line of total lead time v/s
value added time.
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Drilling
200T
Steel
Plant
XYZ
C/T= 1sec
C/O=1 Hr.
Uptime=
80%
23000 sec
avg.
EPE = 2
weeks
I
Tues +
thurs
Process
Outside Sources
Data Box Inventory
Truck Shipment
Push Arrow Finished goods to
customer OR Raw
material from supplier
Super Market
Weld
changeover
Weekly
OXOX
Operator
Kaizen Burst
Manual
Information
Flow
Electronic Information
Flow
Buffer
Schedule
Haijunka Box
Production
Kanban
Withdrawal
Kanban
Transport Cart Kanban Post
Figure: 2
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Physical flows are dealt with inbound raw
materials and processes. For incoming raw materials
information on demand number of deliveries,
delivery quantities, packaging and lead times is
collected. Internal processes use information
concerning the key steps within the organization,
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processing time, and machine down time, inventory
storage points, cycle time, setup time, number of
operations and number of workers, rework, and
quality inspection. Through mapping of value stream,
a current state of whole process from raw material to
finished product may be obtained. For a mass
production all the steps of processes remains same, so
it may be easily clarified where, when, and which
kind of wastes are happened to eliminate. Thus VSM
technique is more effective for job shop production/
Special job production/ discrete production/ batch
shop production. To complete the map, a time line is
used at the bottom of the map to analyze the value
added time and production lead time. Detailed
mapping is done after the completion of big picture
map. There are few questions based on issue related
to the construction of the future state map. They help
to define non mapping details such as production
mix, order release time and also assist to improve the
quality of product as the introduction of Kaizen. As
far as job shop is concerned detailed mapping
provides the guidelines to identify the wastes through
some specified VSM tools such as process activity
mapping, supply chain response array, production
variety funnel, Quality filter mapping, Decision point
analysis, Demand amplification mapping, Physical
structure mapping and research is continuous going
on to provide more effective tools to find most
effective results for a wide range of variety products.
Thus cross functional team is very useful for
knowledge transmission for such a variety of
products Future state value stream map of lean
production line may be shown in figure 4 and
questions for future state mapping may be given as in
table 1.
Terms Future state questions
Basic 1.What is takt time?
2. Will production be directly
to shipping or to a finished
goods?
3.Where will production need
to use pull system?
4.Where can continuous flow be
utilized?
5.What will single point in
production chain will be used
to schedule production?
Heijunka 6.How will the production mix be
leveled at the pacemaker process?
7.What increment of work will be
consistently released from the
pacemaker process?
Kaizen 8. What process improvements will
be necessary?
The Lean Enterprise Research Center
(LERC, 2004) at Cardiff Business School highlighted
that for the most production operations:
5% of activities add value
35% are necessary non value activities
60% add no value at all.
Therefore, no doubt that the elimination of
wastes represent a huge potential in terms of
manufacturing improvements – the key to success in
such a competitive global market. The lean
implementation team is forced to map the lean with
consideration of all six major areas with
corresponding lean practices for the evaluation to
become Lean. The forces for driving a change to lean
may be given as:
The need to fulfill the consumer demand in
an increasingly competitive environment.
The need to be compliant in an increasingly
regulated environment.
The potential benefits:
Customer: Better understanding of consumer
requirement
People: Empowered multi-skilled team at all levels of
functional management & supporting staff.
Quality: More robust processes with lesser error
(Quality improvement, assurance and control)
Financial: Reduction in operating costs, huge capital
avoidance.
Knowledge: A well managed value stream refers a
better system of transmission of knowledge.
Although there are several benefits of being Lean are
reduce inventory, lead time, rework and process
wastages and increase savings, process
understanding, yet to become lean is very difficult
job. Taiichi Ohno who was Architect of Toyota
Production System stated “ Lean methods are so hard
that companies will only try them when they are
desperate”. We have some data, given by LERC
(Lean Enterprise Research Centre) March 2009- Lean
training and support results:
1) 40% of respondents (out of 37 recipients)
reported no change in their training activity
this year.
2) 43% of respondents reported a reduction in
training activity.
3) 8% of respondents reported an increase in
training activity.
4) Most respondents we are looking for lean
courses on lean tools and techniques and
strategy/ leadership rather than consultancy,
monitoring or network membership.
5) 37% though it was important that short courses
were accredited, 30% thinking it was quite
important and 30% thinking it was not
important.
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This data shows that very few manufacturers
are desperate to become Lean due to the lack of
knowledge about the wastes and the non-value added
activities. Through this paper one can understand
how much financial as well as technical benefits may
force Job shop production/ Special job production/
discrete production/ Batch shop production industries
to adopt Lean Practices.
Mapping of Lean Manufacturing Practices to six
impact areas: (Table: 2)
Impact Areas Lean Practices
Customer
Relationship
Customer requirement
Product analysis
Product customization
Product improvement
Demand stabilization
Delivery performance
Value enhancement
Supplier
Relationship
Supplier evaluation
Long term relationship
Cost estimation
Well communication
Product Design
& Development
Product development
based on reliability and
consumer utility
Design for manufacturing
Parts standardization
Consideration of new
techniques such as
concurrent engineering,
reengineering, Business
process reengineering
Workforce
management
Employee evaluation
Total involvement
Pay for performance
Multifunctional workforce
Work delegation
Reward for employee
Shop-floor
management
Lot size reduction
Pull flow control
Production scheduling
Housekeeping (5s’)
Manufacturing
process and
equipment
Setup time reduction
Lead time reduction
Cellular manufacturing
Work standardization
Mistake or error proofing
(Poke-Yoke)
Value recognition
Total Productive
maintenance
Total Quality
Management
Cycle time reduction
Shop-floor organization
These are six impact areas to implement
Lean practices. As far as job shop production is
concerned, it is difficult but essential to implement
Lean with the consideration of all six impact areas for
the survival of the industry in such a competitive
global market to satisfy the consumer. Now-a-days
consumer is the priority for any kind of industry. And
it is well known that the Lean thinking is always
focused on customer, thus Lean has adaptability in
several new fields including the traditional fields of
manufacturing, fabrication and automobile industries.
Table: 2 provide the guidelines to Lean
implementation team through mapping.
In table: 1 the eight questions are given
which must be answered to construct the future state
map. The first five questions are concerned with
basic issues related to the construction of the future
state map. The next two questions deal with technical
implementation details of the control system (e.g.
Heijunka). Ultimately last question in table is related
to assist in the quality improvement and to the
definition of actions needed (Kaizen) to migrate from
the current state to the future state. The final step in
the VSM process is to develop an action plan to
implement the future state. VSM also provides the
information that can be used to conduct economic
justification analysis of the Lean manufacturing cell.
Now-a-days there are many value stream mapping
simulation available. In general we need a
complementary tool with VSM that can quantify the
gains during the early planning and assessment
stages. An obvious tool is simulation, which is
capable of generating resource requirement and
performance statistics whilst remaining flexible to
specific organizational details. It can be used to
handle uncertainly and create dynamic views of
inventory levels, lead times and machines utilization
for different future state map. This enables the
qualification of payback derived from using the Lean
principles. The information provided by the
simulation can enable management to compare the
expected performance of the lean system relative to
that of the existing system, it is designed to replace
(Detty and Yingling, 2000) and assuming that this is
significantly superior, it provides a convincing basis
for the adoption of lean. It may be concluded that
some forces that supporting Job shop production/
Special job production/ discrete production/ Batch
shop production industries for being Lean are:
1) In such an increasingly competitive
environment to fulfill or to get closer to
customer demand.
2) For always being compliant.
3) For the potential benefits.
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VI. Contribution of Study
This study helps to understand the
foundational approach to implement the Lean and
also assist to know the differentiation among Job
shop production/ Special job production/ discrete
production/ Batch shop production and Mass
production regarding their wastes and imperfections.
This study explores, how value stream mapping is
worthy to create the opportunities to use the various
Lean techniques by understanding the respective
losses wastes during the each step of whole process
starting from the raw material and ending to the
customer, by means of this paper researchers and
practitioners can have the fundamentals in the
implementation of Lean and through the deep
assessment incredible results and data may be
predicted very closer to real results after the
implementation of Lean it also enables one to analyze
the benefits of Lean manufacturing for various
sectors such as manufacturing, fabrication, process,
chemical, hospitality, health and food, electronics
industries.
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