Sustainability of the Production Process by Applying Lean Manufacturing Through the PDCA Cycle – A Case Study in the Machinery Industry

Milošević, Marko; Djapan, Marko; D’Amato, Roberto; Ruggiero, Alessandro

doi:10.1007/978-3-030-71956-2_16

Cited by 7 publications

(5 citation statements)

References 18 publications

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“…Similarly, in another study [7], the importance of reducing losses by applying lean production was explained and it was stated that the level of knowledge on this subject should be increased. The results of all these studies on lean production in the construction sector are compatible with the results of this study, which is the first study to measure the knowledge of lean production among building inspection employees; • Both the contribution of lean production in Industry 4.0 [13] and the use of PDCA cycle with lean production [14] studies emphasized the application of lean production in companies for process improvement and sustainability. Considering the importance of raising awareness and education in the application of lean production, the results of these studies are also in line with the results of the study;…”

supporting

confidence: 85%

“…The aim was to ensure the sustainability of the production process and to increase efficiency with lean production tools. By applying the lean manufacturing and PDCA approach with the developed model, productivity performance was increased by 10.67% compared to before the process improvement [14]. Additionally, in another study, modular construction (MC) as a sustainable alternative offered many benefits related to waste reduction, shorter construction times, and increased quality.…”

Section: Methodsmentioning

confidence: 99%

“…Although there are many researchers in different sectors working in this field [5,6,26], etc., the construction sector is still untouched. There are studies on lean production in the construction sector [9][10][11][12][13][14][15]31] (albeit fewer than in industries such as industry, medicine, and economy). However, there has been no study (except for a study by authors) on lean production in inspection institutions in the construction sector [11] which is a sub-branch of the sector and important for the inspection mechanism.…”

mentioning

confidence: 99%

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Investigation of Lean Production Knowledge among Employees in Building Inspection Organizations

Keleş

Yılmaz

2022

Sustainability

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Currently, lean construction has become very important, with lean manufacturing, a philosophy of production that in the most basic sense refers to the elimination of waste and tries to eliminate anything that does not add value to the product or service, emerging as a Japanese business pattern. The aim of this study was to determine the lean production knowledge among employees in building inspection organizations. To measure the level of awareness in construction inspection institutions, which are the leading entities in the construction sector, and the level of awareness on this issue, a survey was conducted through face-to-face meetings with engineering employees residing in Adana province. The results were converted into datasets in the appropriate Microsoft Excel format. With these datasets, the reliability level of the survey was measured using the SPSS program, and the data were analyzed using WEKA software. The study used association rule learning, a data mining method. According to the results, the number of employees who knew the definition of lean production was less than half, at 47%, while the number of those who knew about the concept of lean construction was 44%. The results obtained according to three different class labels were statistically interpreted, and it was determined that the employees lacked knowledge and sufficient awareness about the subject.

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supporting

confidence: 85%

Section: Methodsmentioning

confidence: 99%

mentioning

confidence: 99%

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Investigation of Lean Production Knowledge among Employees in Building Inspection Organizations

Keleş

Yılmaz

2022

Sustainability

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“…value stream mapping (VSM) as the most important tool in lean manufacturing (LM), risk management (RM) as one of the important knowledge in project management, and plan-do-check-act cycle (PDCA) as one of the methods used in businesses for the control and continuous improvement of processes and products. From the literature, the PDCA cycle has been proven to successfully integrate with each VSM Popoola, 2000;Qassim et al, 2015;Garza-Reyes et al, 2018;Milosevic et al, 2021) and RM (Borkovskaya et al, 2018;Labodová, 2004;Okada, 2004;Ren et al, 2017;Qiu, H., & Du, 2021) separately. In this study, the PDCA was used to integrate both VSM and RM and to emphasize the connecting concepts (characteristics) between them.…”

Section: Methodsmentioning

confidence: 99%

Improvement of Value Stream Mapping by Integrating a Monte Carlo Simulation: A Conceptual Model

Araibi,

Ishak,

Shadhar

2023

Management and Production Engineering Review

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Value stream mapping (VSM) is a well-known lean analytical tool in identifying wastes, value, value stream, and flow of materials and information. However, process variability is a waste that traditional VSM cannot define or measure since it is considered as a static tool. For that, a new model named Variable Value Stream Mapping (V-VSM) was developed in this study to integrate VSM with risk management (RM) using Monte Carlo simulation. This model is capable of generating performance statistics to define, analyze, and show the impact of variability within VSM. The platform of this integration is under Deming's Plan-Do-Check-Act (PDCA) cycle to systematically implement and conduct V-VSM model. The model has been developed and designed through literature investigation and reports that lead in defining the main four concepts named as; Continuous Improvement, Data Variability, Decision-Making, and Data Estimation. These concepts can be considered as connecting points between VSM, RM and PDCA.

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“…Through the statistical analysis, the authors confirmed the effectiveness of the continuous improvement processes implemented in the first month. Milosevic et al (2021) implemented the PDCA cycle with Lean tools to ensure the sustainability of the production process of welded excavator frames. The authors refer that the process had a significant performance improvement (10.67%).…”

Section: Introductionmentioning

confidence: 99%

Internal Logistics Process Improvement using PDCA: A Case Study in the Automotive Sector

Amaral

Ferreira

Ramos

2022

Business Systems Research Journal

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Background: The Plan-do-check-act (PDCA) cycle methodology for a continuous improvement project implementation aims for the internal logistics upgrade, which is especially important in the industrial context of a component manufacturing company for the automotive sector. Objectives: The goal is to quantify the gains from waste reduction based on the usage of the PDCA cycle as a tool in the implementation and optimisation of a milk run in an assembly line of a company in the automotive sector by determining the optimal cycle time of supply and the standardisation of the logistic supply process and the materials’ flow. Methods/Approach: The research was conducted through observation and data collection in loco, involving two main phases: planning and implementation. According to the phases of the PDCA cycle, the process was analysed, and tools such as the SIPOC matrix, process stratification, 5S, and visual management were implemented. Results: Using Lean tools, it was possible to reduce waste by establishing concise flows and defining a supply pattern, which resulted in a reduction of movements. The transportation waste was reduced by fixing the position of more than half of the materials in the logistic trailers. The developed Excel simulator provided the logistic train’s optimal cycle time. Conclusions: The assembly line supplied by milk-run was fundamental to highlight a range of improvements in the process of internal supply, such as better integration of stock management systems, greater application of quality, or the adoption of better communication systems between the different areas and employees.

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Sustainability of the Production Process by Applying Lean Manufacturing Through the PDCA Cycle – A Case Study in the Machinery Industry

Cited by 7 publications

References 18 publications

Investigation of Lean Production Knowledge among Employees in Building Inspection Organizations

Investigation of Lean Production Knowledge among Employees in Building Inspection Organizations

Improvement of Value Stream Mapping by Integrating a Monte Carlo Simulation: A Conceptual Model

Internal Logistics Process Improvement using PDCA: A Case Study in the Automotive Sector

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