Purpose -This research was conducted to study benefits of a concept, known as lean manufacturing, which elicits organizations to do more with less effort, time, space, and equipment by eliminating waste. Because lean implementation involves finances, dedication, and cultural change in business, there is a need to assess a company's lean initiative. Design/methodology/approach -A comprehensive lean assessment tool is designed targeted for use by manufacturing companies. Research of lean principles and practices was conducted through lean organizations, trade publications, manufacturing web sites, professional articles, textbooks, lean exhibitions, and non-profit lean organizations. Findings -This led to the development of a lean survey questionnaire delivered to 143 lean companies and lean consultants for authentic input. Based on the response, survey participation met a goal of 95 percent accuracy with 15 percent error. Completed surveys were compiled and analyzed for fundamental practices of lean organizations. Answers to the survey were assigned numerical values based on lean significance, and a lean assessment model was developed based on Excel. The lean assessment model was fine-tuned and programmed to output a numerical and descriptive lean assessment grade. It was tested for soundness by inputting mock lean and traditional company answers into the model. Output results from the model correlated with the input. Originality/value -Lean thinking philosophy and lean manufacturing methods and principles were exhaustively researched to make a successful lean organization. The research led to the development of a visual indicator, the Lean Thinking Management Wheel. This model to assess lean thinking manufacturing initiatives unique and has a great potential to use industry wide.
Cell-load variation is considered as a major shortcoming in cellular manufacturing systems. It can cause long queues in front of machines and impose extra costs to the cellular layouts. In this paper the impact of inflation on cell-load variation in cellular manufacturing systems is examined. For this purpose, a new method is proposed for scheduling dynamic cellular manufacturing systems in the presence of bottleneck and parallel machines. The aim is finding the trade-off values between in-house manufacturing and using outsource services while system costs are not deterministic and may be varied from period to period by inflation. To solve the model, a hybrid genetic and simulated annealing algorithms is developed because of the high potential of outcomes to be trapped in the local optima. The results are then compared in LINGO® 12.0 software. In continue a Taguchi method (an orthogonal optimization) is used to estimate parameters of the proposed method in order to solve experiments derived from literature. Our findings show that the condition of dynamic costs affects the routing of materials in process and may induce machine-load variation that yield to cell-load diversity. An increase in changing costs causes the loading level of each cell to vary, which in turn results in the development of "complex dummy sub-cells." To measure the level of cell-load variation a new mathematical index is developed. Then, a new method is proposed for minimizing cell-load variation in the mentioned condition by using control lines. The results indicate that the proposed method can significantly reduce the level of cellload variation in CMS.
This paper aims to improve the implementation standards of solar-energy-based street lighting in Indonesia. A model framework was developed to assess existing conditions regarding the level of lux, the distance between poles, pole height, and lamp power. According to the evaluation of the existing circumstances, the street lighting system is not satisfactory according to the national standard, with 64.7% black area. An alternative installation of street lighting designed by DIALux application was proposed to fulfill the technical standard of street lighting. The result shows that this alternative design can be used for renewing existing street lighting with better performance and reliability. Economic analysis of all technically feasible alternatives was conducted afterward by benefit–cost analysis. The analysis shows that solar-energy-based street lighting requires as much as 621,473,620.00 Indonesian Rupiah (IDR), with 1.06 benefit–cost ratios and a 9% reduction of total cost. Therefore, the analysis indicates that solar-energy-based technology can be feasibly implemented in a street lighting system. The results show that the proposed model can be applied to improve the implementation standard of solar-energy-based street lighting.
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