PurposeThis research aims to identify lean tools and techniques that are needed to be implemented to improve the performance in the fabrication industry. The objective is to find the wastes in manufacturing processes using value stream mapping (VSM) and prioritize the lean tools suitable to enable the attainment of leanness and streamline the processes.Design/methodology/approachVSM tool is applied in the industry to construct the current state map, identify improvement proposals and implement in future state. Fuzzy technique for order performance by similarity to ideal solution (TOPSIS), a multi-criteria decision-making technique (MCDM), is used to prioritize the identified improvement proposals. This study observed that mistake-proof processing and layout organization are the two techniques with the top priority that needs further improvement to enhance the leanness of the organization.FindingsUpon successful implementation, the cycle time is reduced by 14.97%, and total inventory is reduced by 45.67% which leads to the improvement of value addition from 5.88 to 9.21%. Although lean has been adopted for many years, implementation of lean in the fabrication industry has been limited.Practical implicationsThis study addresses the challenges in terms of implementing lean in fabrication industries and practical implications of lean tools and techniques and the prioritization of lean concepts against various lean criteria to enable leanness.Originality/valueThe deployment of improvement prioritization tool integrated with VSM in the context of a fabrication industry is the original contribution of the authors.
Purpose The purpose of the paper is to depict a study on analysis of barriers to lean adoption in fabrication industry using interpretive structural modelling (ISM). Design/methodology/approach From the literature review, 22 barriers to lean adoption in fabrication industry have been recognized . Self-structure interaction matrix has been developed based on expert opinion. Computational steps of ISM are being done to develop the structural model. cross-impact matrix multiplication applied to classification (MICMAC) analysis is being done to group the barriers into four types. Findings Based on the study, it has been found that “lack of knowledge about lean (philosophy, principles, tools)”, “lack of top management support and commitment” and “poor leadership” are found to be the principal barriers. MICMAC analysis indicated that number of driving, dependent, linkage and autonomous barriers are 9, 8, 4 and 1, respectively. Practical implications The study has been executed based on the inputs from industrial practitioners and hence the inferences are found to have practical relevance. Originality/value The study is an attempt to analyze the barriers for lean concepts adoption in fabrication kind of industry.
PurposeThe purpose of this paper is to report a review of various perspectives of lean in heavy engineering and fabrication industries and to propose a framework.Design/methodology/approachLean manufacturing (LM) earlier known as Toyota Production System (TPS) was mainly used by automobile industries where the operations occur in sequence and the adoption of LM was easier. When it comes to heavy engineering industries, the concept of lean can be adopted in a versatile operating environment to have more advantages by waste elimination thereby having higher profit. Thus, an effort is made to consolidate various lean perspectives, namely, barriers, principles, tools and performance measures and a framework was proposed on how various lean perspectives can be adopted in a systematic way.FindingsA comprehensive analysis of lean from various perspectives from viewpoint of the fabrication industry are done and the review is presented. Also, the framework linking barriers, principles, tools and performance measures is being contributed as an outcome of the review.Originality/valueThe review of lean from various perspectives for the fabrication industry and the development of a framework is the original contribution of the authors.
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