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EN
This study aims to explore the predominant critical success factors (CSFs) for the implementation of lean manufacturing (LM) in small and medium-sized enterprises (SMEs) producing machinery and equipment (M&E). The convergent parallel mixedmethods (qualitative and quantitative) were employed in three Malaysian M&E manufacturing SMEs. The study identified four predominant CSFs that significantly impact on the LM application in M&E manufacturing SMEs, namely, leadership and commitment of the top management, training to upgrade skills and expertise, employee involvement and empowerment, and the development of LM implementation framework for SMEs. This study can assist the M&E manufacturing SMEs in prioritising these predominant CSFs so that the management teams can work on the improvement strategy and achieve a higher level of lean sustainability. It offers valuable insights into the LM implementation that could provide a practical reference guide to other industrial companies.
EN
Application of selected quality tools to increase machine efficiency in a production enterprise Maintaining the company’s technical infrastructure in an appropriate condition is a prerequisite for ensuring stability in the implementation of production processes. The effectiveness of actions implemented to achieve this goal improves the use of adequate quality methods and tools. This article shows the practical implications of tools such as Pareto analysis, Ishikawa diagram, MTTR, MTBF to increase the efficiency of machine operation by eliminating the main causes of downtime of an automatic molding line and implementing effective corrective actions.
EN
A robust manufacturing sector is imperative for achieving sustainable and inclusive development. Also, in the Indian context, Micro, Small and Medium Enterprises (MSMEs) are of vital importance due to their contribution to GDP, exports and employment. Indian Government has launched many schemes to vitalize and improve the competitiveness of Manufacturing MSMEs. ‘Lean Manufacturing Competiveness Scheme’ (LMCS) is a huge step aimed to act as a catalyst for lean adoption by Indian MSMEs. This paper uses SAP LAP framework to address critical questions regarding lean adoption by Indian manufacturing MSMEs in the context of the government scheme ‘LMCS’. The study adds to the existing body of knowledge on lean manufacturing that emphasizes on the importance of soft issues while implementing lean. It also benefits the stakeholders by suggesting suitable actions that can be taken to further improve the competitive priorities of MSMEs.
EN
Studies linking the use of lean practices to company performance have been increasing as markets are becoming more competitive and companies are eager for reducing waste and therefore implementing the Lean Management (LM) philosophy to improve performance. However, results from these studies have found various and different impacts and some light is needed. Extant literature was reviewed and, to achieve the research objective, a metaanalysis of correlations was carried out. The obtained results suggest a positive relationship between some lean practices and performance measures. Furthermore, the presence of moderators influencing the relationship between lean practices and performance outcomes is highlighted in our results. To our best knowledge, this is the first research that proposes a comparison of results from primary studies on Lean implementation, by analysing the linear relationship between lean practices and enterprise performance. It fills this gap and therefore represents an important contribution.
PL
Problemem badawczym podniesionym w pracy było przedstawienie roli szczupłego wytwarzania w kształtowaniu sprzedaży produktów badanych przedsiębiorstw. Praca składa się z dwóch zasadniczych części. W pierwszej części zaprezentowano istotę i zasady szczupłego wytwarzania w zarządzaniu przedsiębiorstwem. W drugiej części przeprowadzono studium przypadku, w którym analizie poddano badanie rentowności sprzedaży w kontekście implementacji szczupłego wytwarzania zrealizowane w trzech przedsiębiorstwach branży chemicznej. Metodami badawczymi zastosowanymi w pracy były studia literaturowe, studium przypadku oraz metodę opisową i analizę trendu. Z przeprowadzonego studium przypadku wynika, że decyzje w obszarze rentowności sprzedaży powinny uwzględniać instrumenty szczupłego wytwarzania, które optymalizują koszty prowadzonej działalności.
EN
The research problem raised at work was to performance the role of lean manufacturing in shaping sales of products of the surveyed enterprises. The work consists of two parts. The first part discussed the essence and principles of lean manufacturing in business management. In the second part, a case study was carried out, in which the sales profitability analysis in the context of the implementation of lean manufacturing carried out in three companies of the chemical industry was analyzed. The research methods used in the work were literature studies, a case study, a descriptive method and trend analysis. The case study shown that decisions in the area of sales profitability should include instruments of lean manufacturing, which optimizing the costs of operations.
EN
The research problem raised at work was to examine the role of lean management in shaping sales and implementation of the strategy. The work consists of three parts. The first part discussed decision making in relation to the implementation of the company's strategy. The second part presented the essence and principles of lean manufacturing in business management. In the last part, a case study was carried out, in which the sales profitability analysis in the context of the implementation of lean manufacturing carried out in three companies of the chemical industry was analyzed. The research methods used in the work were literature studies and index analysis. The case study shown that decisions in the area of sales profitability should include instruments optimizing the costs of operations.
PL
Problemem badawczym podniesionym w pracy było zbadanie roli szczupłego zarządzania w kształtowaniu się sprzedaży oraz realizacji strategii. Praca składa się trzech części. W pierwszej części omówiono podejmowanie decyzji w odniesieniu do realizacji strategii przedsiębiorstwa. W drugiej części zaprezentowano istotę i zasady szczupłego wytwarzania w zarządzaniu przedsiębiorstwem. W ostatniej części przeprowadzono studium przypadku, w którym analizie poddano badanie rentowności sprzedaży w kontekście implementacji szczupłego wytwarzania zrealizowane w trzech przedsiębiorstwach branży chemicznej. Metodami badawczymi zastosowanymi w pracy były studia literaturowe oraz analiza wskaźnikowa. Z przeprowadzonego studium przypadku wynika, że decyzje w obszarze rentowności sprzedaży powinny uwzględniać instrumenty optymalizujące koszty prowadzonej działalności.
EN
Paper presents a proposal for improvement of implementation concerning one of Lean Manufacturing (LM) tools, in particular 5S method. For that purpose there was applied Failure Mode and Effects Analysis (FMEA) in simplified form. A test analysis concerning implementation of the 5S method in one of Subcarpathian companies was performed by a team consisting of workers involved in that implementation of and external experts. Results of that analysis showed that the biggest difficulties playing role in implementation of the FMEA are the ones associated with laziness of workers and shortage of understanding advisability of 5S implementation. Obtained results are aimed at improving implementation of the 5S method in the company. They might be, however, also helpful in implementation of that method in other enterprises.
EN
The concept of lean management in an organization, improving products and processes using the Lean Manufacturing concept, is discussed in this paper. Striving for excellence is the key factor in maintaining competitiveness on the market. Only organizations able to adapt to changing environ-mental conditions faster than others achieve an advantage, and the management in line with the Lean Manufacturing philosophy is de facto change management. In this paper, important factors in the ceramic industry, which should be taken into account when implementing Lean Manufacturing are characterized. Important factors affecting the implementation of lean tools include, such as: the size of the enterprise, involvement of employees, knowledge about the Lean concept, technological factor, type and variety of the product line, as well as the specificity of the ceramic industry. The greatest opportunity associated with the implementation of Lean is to increase the competitiveness of the company obtained through: meeting the quality and economic expectations of customers. The greatest opportunity associated with implementation of the Lean is to increase competitiveness of the company obtained through: meeting the quality and economic expectations of their customers. Practice shows, however, that despite the simplicity of rules and tools, few organizations manage to achieve the level of excellence of the pioneer of this concept, the Japanese Toyota Corporation.
EN
The paper discusses possible applications of wireless technologies in support of lean manufacturing tools. The typology of lean tools is provided. It distinguishes three main categories, which are identification and analysis of waste, improvement implementation, and process monitoring. The set of lean tools was analyzed in terms of information requirements. On the other hand, the typology of wireless technologies was discussed including RFID and Wi-Fi. The literature review of wireless technology applications for support of lean tools was conducted. The literature was systematically reviewed from the point of view of specific technologies and specific tools which were the subjects of the analyzed publications. Both typologies were synthesized to establish a framework for wireless technologies applications in the context of lean manufacturing implementation. It also could serve as a guideline for lean practitioners and implies future research directions. This paper is an extended version of paper published by [1].
EN
Lean has established itself as the primordial approach to obtain operational excellence. Its simple and intuitive techniques focus on reducing lead time through continuous improvement, involving all levels of employees in the organization. However, the rate of successful implementations has remained low. This paper contributes to the understanding of continuous improvement in a Lean context, by analyzing a database of almost 10.000 improvement actions, from 85 companies, covering the time frame 2010–2018. It discusses categories of actions, their impact and cost, as well as key characteristics of the companies. It proposes an objective criterion to identify “success” and “failure” in Lean implementation and tries to link these to operational results. It is probably the first time an analysis of this magnitude on the subject has been performed.
EN
One of the key factors of a competitive economy is creating a strong, internationally competitive SME sector. This essay is based on the fact that management tools used in the SME sector are insufficient. With the development of these tools, the competitiveness of companies could improve. According to the literature, using lean thinking has a positive influence on the company’s effectiveness, and also proved that lean approach can be successfully extended out of the car industry, into the limitedly resourced SME sector, too. Even though the topic of lean manufacturing is analysed by many studies, there is a lack of papers dealing with its usage in the SME sector. The originality of this paper lies in analysing the current status of using lean manufacturing practices among the Hungarian SMEs operating in the manufacturing industry. The paper includes an examination about how deeply the elements of lean thinking are present in the Hungarian SME sector, how large the development reserves are, and whether there is a difference between the usage of lean practices. A structured questionnaire was used for data collection. SMEs’ representatives, mostly CEOs and managers from the Hungarian manufacturing industry participated in the survey. The sample contained 128 observations. The study has two control variables, which are the size of the company and the relation to the lean management. The survey brought the following results. First of all, it shows that the level of using lean is low among the Hungarian SMEs. Furthermore, customer orientation is a key factor in the sector, however, there are considerable possibilities for progress by the inner processes and the handling and involvement of the suppliers. Firstly, a good basis to increase the effectiveness could be the creation of thinking in processes influencing the supply chain. Secondly, the development of the leadership and the involvement of the employees at some level are also significant. Key findings is that without state incitement and the involvement of outside experts, progress cannot be expected to spread on a broad scope. The background of the research method was created to fit the available literature and to capable to be used in other countries, too. Moreover, this way the available information can be expanded with a regional dimension, in case further studies are going to be made.
EN
The purpose of this research is to develop a Lean-RFID based waste identification system (LRWIS) for small-medium manufacturing companies. The specific objective of this research is to develop and implement the LRWIS from integrating the appropriate lean tools and advanced technologies for wastes reduction and inventory management. Subsequently, the framework was converted into a system for a small-medium sized wood processing manufacturer in Malaysia and integrated into a computerized program. The LRWIS can monitor real-time inventory and production status so the manufacturer can optimise the quantity of the primary products and deliver them on time as per the RFID information of each container. The manufacturer can also make decision instantly for controlling and changing different products in the production progress. The system provides simple constructed framework under a low cost infrastructure, yet it is of practical value in reducing the wastes and also optimising the production process.
14
Content available remote Ocena wskaźnikowa mapy strumienia wartości
PL
Mapa strumienia wartości (Value Stream Map) jest jednym z podstawowych narzędzi koncepcji oszczędnego wytwarzania ( lean manufacturing). Sporządzenie mapy strumienia wartości nie powinno być samo w sobie głównym celem firmy. Kluczowa jest bowiem jej analiza, której podstawowym rezultatem winno być opracowanie koncepcji usprawnienia strumienia wartości (przekłada się to na obniżenie kosztów). W pracy autor zaproponował metodę analizy wskaźnikowej mapy strumienia wartości. Oparta jest ona o dwa podstawowe wskaźniki wynikające z wspomnianej mapy: wskaźnik czasu przepływu (Flow Time Indicator) oraz wskaźnik płynności przepływu FSI (Flow Smoothness Indicator). Na przykładach pokazano sposób obliczania i interpretacji obu wskaźników. Artykuł zakończono krótką informacją o aspektach praktycznych przemysłowego zastosowania analizy.
EN
The value stream map is one of the basic tools of the lean manufacturing concept. Creating a value stream map should not be in itself the main goal of the company. The key is its analysis, the main result of which should be the concept of streamlining the value stream (this translates into lower costs). In the work, the author proposed a method of index analysis of the value stream map. It is based on two basic indicators resulting from the above-mentioned map: flow time indicator (Flow Time Indicator) and FSI flow smoothness indicator (Flow Smoothness Indicator). The examples show how to calculate and interpret both indicators. The article was concluded with a brief information on the practical aspects of the industrial application of the analysis.
15
Content available remote Implementacja narzędzia lean manufacturing w wybranym przedsiębiorstwie
PL
Celem artykułu jest przedstawienie zastosowania lean manufacturing w wybranym przedsiębiorstwie. Na wstępnie autorzy opisują definicję i zastosowanie lean manufacturing oraz jedno z narzędzi jakim jest TPM (Total Productive Maintenance). W kolejnym punkcie opisano proces produkcyjny w analizowanym przedsiębiorstwie, stan przed i po wprowadzeniu TPM. Na zakończenie przedstawiono wnioski z analizy.
EN
The aim of the article is to present the application of lean manufacturing in a selected company. Initially, the authors describe the definition and use of lean manufacturing and one of the tools that TPM (Total Productive Maintenance) is. The next section describes the production process in the analyzed company before and after TPM. At the end, the conclusions from the analysis are presented.
16
PL
Artykuł opisuje możliwość wykorzystania narzędzi szczupłego zarządzania do doskonalenia procesów produkcyjnych w małych przedsiębiorstwach. Porusza kwestię obaw związanych z koncepcją Lean oraz wskazuje przyczyny świadczące o konieczności jej wdrożenia. W ramach studium przypadku nawiązano współpracę z rodzinną firmą produkcyjną, zlokalizowaną na terenie Dolnego Śląska, specjalizującą się w produkcji wyrobów dostosowanych do indywidualnych potrzeb klientów. Bazując na pomiarach i obserwacjach przeprowadzonych na reprezentatywnych procesach, zidentyfikowano różne typy marnotrawstwa, którego wyeliminowanie pozwoliłby na rozwój firmy. Występujące problemy zobrazowano dodatkowo przy pomocy schematu przepływu materiału oraz diagramu spaghetti.
EN
The paper describes the possibility of using lean management tools to improve production processes in small enterprises. It raises the issue of concerns about the Lean concept and indicates the reasons for its implementation. As a part of the case study, a cooperation was established with a family production company located in Lower Silesia, specializing in the production of products adapted to the individual needs of customers. Based on measurements and observations carried out on representative processes, various types of waste were identified as a potential for improvement. The problems appearing are illustrated with the use of the material flow diagram and the spaghetti diagram.
PL
W pracy przedstawiono wyniki wdrożenia koncepcji Kompleksowego Utrzymania Ruchu (TPM) w jednym z zakładów produkcyjnych na terenie Polski, będącym filią międzynarodowej korporacji działającej w branży elektrotechnicznej. Celem badania było potwierdzenie korzyści uzyskiwanych z programu TPM, jednakże na poziomie całego zakładu. Było to zadanie złożone dla tego studium przypadku z uwagi na różnorodność i ilość wyposażenia produkcyjnego. Zebrane dane na przestrzeni ostatnich kilku lat poddano analizie, a jej wynik potwierdza nie tylko słuszność postawionej tezy o skuteczności koncepcji TPM do obniżenia poziomu awarii, ale również daje rekomendacje dla dalszego rozwoju koncepcji w tej firmie i wskazówki dla zarządu. W artykule podkreślono również efekt współdziałania koncepcji TPM z innymi programami ciągłego doskonalenia.
EN
This paper presents a substantial results of the concept of Total Productive Maintenance in one of production sites in Poland, which is a subsidiary of an international corporation operating in the electronic industry. The aim of the study was to confirm the common benefits derived from the TPM program, but at the level of the whole plant, which was a complex task for this case study because of the variety and quantity of production equipment utilized. The data collected over the last few years were analyzed, and the result confirms not only the validity of the bet thesis about the effectiveness of TPM to reduce the level of breakdowns but also gives recommendations for the further development of the improvement initiative in this company and guidance to the board. The article also highlights the effect of interaction between TPM and other programs of continuous improvement.
PL
Artykuł przedstawia technikę Lean Manufacturing, która jest odpowiedzialna za likwidowanie marnotrawstwa w przedsiębiorstwie. Dąży do stworzenia przedsiębiorstwa „idealnego”, które będzie spełniało perfekcyjnie oczekiwania swoich klientów przy jednoczesnym wysokim poziomie satysfakcji pracowników.
EN
The paper presents Lean Manufacturing techniques, which contribute to reduction of waste in enterprises and aim at formation of perfect companies which meet expectations of customers and maintain high level of satisfaction of employees.
19
Content available Lean production development in SMEs: a case study
EN
The competitiveness of small and medium sized enterprises (SMEs) is vital for the European economy. Also, manufacturing is often the core competence of SMEs. Adopting lean philosophy is a viable and popular approach for developing production and enabling continuous improvement. Despite the increased interest in empirical lean research, the body of knowledge about lean manufacturing development in SMEs is currently insufficient. This paper describes a study of a lean development project in a Finnish-based manufacturing SME. A current state analysis and development proposals are presented. The project applies a framework that other SMEs can utilize in identifying their problem areas and creating development proposals for their production activities. The results of the study contribute to the existing body of knowledge in lean manufacturing. In addition, managers in SMEs can utilize the study results as a reference when designing production development projects.
PL
Artykuł przedstawia koncepcję wykorzystania wybranych metod lean production. Techniki i metody wchodzące w skład lean manufacturing pozwalają na systematyczną identyfikację i eliminację marnotrawstwa poprzez ciągłe doskonalenie procesów logistycznych w przedsiębiorstwach produkcyjnych. Zmniejszenie kosztów i poprawa jakości produktu oraz dostosowanie produktu do wymagań klienta ma kluczowe znaczenie w uzyskaniu przewagi konkurencyjnej. Wiąże się to często ze zmianą podejścia zarządu do kwestii utrzymania maszyn, zwłaszcza zwiększenia ich bezawaryjności oraz uzyskania większej elastyczności produkcji. Cele te można uzyskać poprzez wykorzystanie metod z obszaru lean production.
EN
The paper presents a concept of using selected lean production methods. The lean manufacturing methods and techniques allow a systematic identification and elimination of waste by continuous improvement of logistics processes in manufacturing companies. Reduction of costs and improvement of product quality has a key importance in gaining competitive advantage. This is often related to maintenance of machines, particularly increasing their reliability and obtaining better production flexibility. Those objectives can be achieved by using lean production methods.
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