Lean techniques impact evaluation methodology based on a co-simulation framework for manufacturing systems

Abstract

Lean implementation plays a major role in optimizing productivity and reducing waste. Applying the adequate integration of Lean Techniques (LT) can ensure a higher profitable benefit. Many companies face difficulties in choosing the LT that best suit their situations to reach their objectives. In this study, we propose the simulation of specific modeled industrial contexts and check the impact of implementing LT simultaneously. Market fluctuation, demand diversification, and uncertainty of resources contexts are studied to perceive how LT behaves accordingly. Four KPIs (Key Performance Indicators) are retained for the analysis: Work in Progress, Lead-time, Production Throughput, and Defect Rate. An aeronautical company is modeled and experiments are performed to demonstrate the usefulness of a developed co-simulation framework to perceive the sensitivity of LT to some industrial contexts. The results showed that Poka Yoke and 5S are context-free LT valid in any industrial context. Pull, SMED, and Cross training are contextual and deserve careful applicability regarding the simulated context. Cross training, suitable for uncertainty of resources, does not show any significant improvements when the company was exposed to market fluctuations and demand diversification contexts.

HLA-based time management and synchronization framework for lean manufacturing tools evaluation

“…In the Pull scenario, when a machine’s work in progress (WIP) surpasses a preset number of units, it sends a signal to the upstream machine to cease supplying items in process. 22,12,44…”

“…FMI lacks the time management and synchronization features found in the HLA standard. 11 In FMI, programmers must create a master algorithm to coordinate the steps of the co-simulation. The master algorithm is responsible for the synchronization and the exchange of data between the simulation models.…”

“…In the Pull scenario, when a machine's work in progress (WIP) surpasses a preset number of units, it sends a signal to the upstream machine to cease supplying items in process. 22,12,44 SMED is designed to reduce/eliminate waste caused by a shortage of materials, to keep tools and machines clean, and to manage the workshop space associated with setup/changeover procedures. SMED decreases the changeover time required to setup a machine.…”

“…9,10 One of the major challenges that managers face is the difficulty to choose the Lean tools and techniques that best fit their company and lead toward better productivity and quality. [11][12][13][14] Managers are not taking into consideration the context in which Lean tools should be applied, they often rely on their own experience and subjective appreciation. However, there exists a relation between the context and Lean techniques.…”

Methodology combining industry 4.0 technologies and KPI’s reliability for supply chain performance

“…Bring high rate of quality is important and lead the manufacturing rate down by eliminating the waste and non-value added work is recommended (El kihel et al 2019;Dhiravidamani et al 2018;Qi et al 2017). Context importance to deploy the relevant Lean practices in aeronautic SC has been studied and confirmed in (Amrani and Ducq 2020;Possik et al, 2021). Later, the SC evolved towards other dimensions considering social and environmental perspectives to guarantee efficiency not only from economic perspective but ensuring sustainable organizations and making eco-friendly products (Wang, Zhang and Zhu 2017).…”