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1

Improving business maintenance processes using Lean Manufacturing tools - case study

Radecka Katarzyna

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

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2022

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z. 156

395--405

EN

Objective: The aim of this article is to analyze and evaluate the introduction of selected Lean Manufacturing tools into the management of a given enterprise, the task of which is to increase the efficiency of the machine park and improve the quality of finished products. The introduced changes are also expected to increase the detectability of waste, avoid unnecessary stopping of machines and unplanned stoppages. Design/methodology/approach: As part of the research, the internal materials of the surveyed company were analyzed and free interviews with employees and specialists of the plant were conducted. An efficiency analysis of the production process was carried out. Findings: In order for the improvement of technical progress to function well, the requirement of an appropriate technical condition and the course of technical progress. The entire process flow of the product should be analyzed. Research limitations/implications: Subjectivity of the analysis thanks to the use of a qualitative approach in research. Future research may be related to creating a mentoring program in the area of interest. Practical implications: The results of the study can be used as input data for the design of training programs in the study area. Social implications: The concept of lean manufacturing is a tool for constant changes that can be observed both in the modern economy and in society. They require dynamic flexibility from entrepreneurs and looking for solutions that can optimize production processes. The concept includes a slogan such as corporate social responsibility, which grew out of sustainable development. It is prioritized by managers of various companies. Therefore, this work deals with the subject of Lean Management as an instrument of responsible business. Originality/value: This article is addressed mainly to companies that want to implement and improve Lean Manufacturing tools. It shows how companies can improve selected areas of production.

2

Wybrane aspekty produkcji prefabrykatów w kontekście technologii BIM

Nicał Aleksander

Nowoczesne Hale

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2022

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Nr 4

62--68

PL

W artykule przedstawiono wybrane zagadnienia dotyczące produkcji prefabrykatów w kontekście technologii modelowania informacji o budynku (BIM). Technologia BIM staje się coraz bardziej obecna w budownictwie oraz w obszarze zautomatyzowanej produkcji prefabrykatów budowlanych. Artykuł opisuje m.in. genezę technologii BIM, jak również początki systemów projektowania wspomaganego komputerowo (CAD) i komputerowego wspomagania wytwarzania (CAM). Dodatkowo w artykule opisano podstawowe zalety płynące z zastosowania tej technologii w prefabrykacji. Uwagę poświęcono także koncepcji lean manufacturing i Systemowi Produkcyjnemu Toyoty (TPS), jako bardzo istotnym czynnikom w funkcjonowaniu obecnych zakładów produkcyjnych. W końcowej części artykułu odniesiono się do platformy planowania trójwymiarowego o nazwie Techniczny Informacyjny/Integracyjny Manager (Tim). Przedstawiono jej moduły oraz dokonano ich podstawowego opisu.

EN

The paper presents selected issues related to the production of precast concrete elements in the context of Building Information Modeling (BIM). The BIM technology is becoming more and more present in the construction industry and in the area of automatem production of precast concrete building elements. The article describes, among others, the genesis of BIM as well as the beginnings of computer-aided design (CAD) and computeraided manufacturing (CAM). Moreover, the main advantages of using this technology in prefabrication are presented. Attention is also paid to the concept of lean manufacturing and the Toyota Production System (TPS) as very important factors in the functioning of current production plants. At the end of the article, reference is made to the three-dimensional planning platform called the Technical Information/Integration Manager (TIM). Its modules and their basic description are also included.

3

Visual Performance Management as a Cascade-participatory Information Exchange System, In-depth Manufacturing Study

Urban Wiesław, Zawadzki Artur

Management and Production Engineering Review

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2022

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Vol. 13, No. 1

19--31

EN

This study is aimed at investigating the functionality of Visual Performance Management (VPM), along with determining the necessary features such a method should demonstrate to be an effective and meaningful tool for the development of Lean Management in an organisation. Based on the analysis of a case study in a large manufacturing organisation, a crosscutting assessment of such a system was made, a literature review proves the lack of such a comprehensive study. Six critical features of VPM were identified, they are very practical and giving many interesting insights into studied Lean method. The view emerged from empirical investigated shows VPM as of the wider functionality then only visual information exchange methodology. The VPM serves as cascade information exchange system and has substantial potential to support employee’s participation.

4

Human resources quality improvement from the perspective of Kaizen practice

Minh Nguyen Dat, Quyen Nguven Thi Hanh

Management

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2022

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Vol. 26, no. 1

144--164

EN

Kaizen has long been known as an improvement philosophy that starts with small frequent changes to make larger changes in production. These changes come from the ideas and creative thinking of employees to ensure that the production conditions and processes are continuously improved. However, Kaizen not only helps motivate employees to think creatively with effective methods and skills, but it also helps them develop their capabilities, personality, and good work habits. The purpose of this paper is to show a new approach to human resources quality improvement through the Kaizen philosophy as a sustainable and active strategy to improve work performance. With analytical research on the relationship between Kaizen implementation, human resources quality improvement, and production efficiency and exploratory research on particular cases in manufacturing enterprises in Vietnam, the authors point out changes in production efficiency and human capacity before and after implementing improvement (Kaizen) projects. The paper finds significant changes of employee capability (Kaizen practitioners) after evaluating the human resource development process on the basis of six indicators of two groups (namely capacity development, personality development) and a set of criteria using a 5-point scale. In addition, the paper proposes a PDCA based framework with 12 contents corresponding to stages of the human resource development. This paper extends theories related to Lean Manufacturing or Kaizen, highlighting how philosophy of Kaizen has hard and soft impacts on the improvement of performance and human resources.

5

Lean inventory management of an industrial tool distributor in Thailand using a data visualization tool

Kongprasert Nattapong, Garrett Tuchcha, Saengphueng Sompop

Zeszyty Naukowe Politechniki Poznańskiej. Organizacja i Zarządzanie

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2021

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Nr 84

111--123

EN

Inventory management continues to play a critical role in the success of an organization. It is the collection of all the materials and goods stored, whether for use to complete the production process or for sale to the customer. The efficiency of inventory management is a challenge for all companies that have a warehouse or distribution center. Therefore, all firms need to adapt their business strategies to survive in a highly competitive market by applying tools or systems to support inventory control and management. This research was conducted to increase the efficiency of inventory management of an industrial tool distributor in Thailand by using the data visualization tool. It focused on the inventory planning process. Lean manufacturing was implemented to identify, improve and eliminate unnecessary activities in operations. Microsoft Power BI is a data visualization tool that was used in this study to support officers in operational decision-making and planning. It facilitated the monitoring of inventory levels, evaluating the value of inventory, and analyzing the key vendors on an almost real-time basis. The results showed that unnecessary activities were improved and simplified by integrating the data visualization tool. The lead time of the inventory planning process was decreased by 76.19% from 10.5 days to 2.5 days per time. It can increase the efficiency of inventory management.

PL

Zarządzanie zapasami nadal odgrywa kluczową rolę w sukcesie organizacji. Zapasem określa się wszystkie materiały i towary przechowywane w celu wykorzystania ich do procesu produkcyjnego czy też sprzedaży klientowi. Efektywność zarządzania zapasami jest wyzwaniem dla wszystkich firm, które mają magazyn lub centrum dystrybucyjne. Wszystkie firmy muszą dostosować strategie biznesowe, aby przetrwać na wysoce konkurencyjnym rynku. W tym celu stosuje się narzędzia lub systemy wspomagające kontrolę i zarządzanie zapasami. Przeprowadzone badanie miało zwiększyć efektywność zarządzania zapasami dystrybutora narzędzi przemysłowych w Tajlandii za pomocą narzędzia do wizualizacji danych. Skupiono się na procesie planowania zapasów. Wdrożono koncepcję zarządzania szczupłego w celu identyfikacji, poprawy i eliminacji zbędnych działań w operacjach. Do wizualizacji danych zastosowano Microsoft Power, które zostało wykorzystane w tym badaniu do wspierania pracowników w podejmowaniu decyzji operacyjnych i planowaniu. Umożliwiło ono monitorowanie poziomów zapasów, ocenę ich wartości oraz analizę kluczowych dostawców w czasie niemal rzeczywistym. Wynik pokazał, że zbędne czynności zostały usprawnione i uproszczone dzięki integracji narzędzia do wizualizacji danych. Czas realizacji procesu planowania zapasów został skrócony o 76,19% z 10,5 dnia do 2,5 dnia. Przeprowadzone badania stanowią przykład, jak można zwiększyć efektywność zarządzania zapasami.

6

The impact of Lean Manufacturing on enviromental performance in Moroccan automotive industry

Bouazza Yassine, Lajjam Azza, Dkhissi Btissam

Management Systems in Production Engineering

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2021

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nr 3 (29)

184--192

EN

Due to an increase in energy price and pollution plus environmental regulations, companies start to adopt green policies. In fact, companies are encouraged by governments to develop strategies to achieve more sustainable operations. Based on this literature review the contribution of Lean Manufacturing on environmental performances will be discussed, a survey of 50 different automotive companies based in Morocco, shows how they are carrying out manufacturing and environmental practices. The result of this study shows a positive impact of advanced Lean Manufacturing’s tools on the environmental performance and contribute to the present literature on environmentally friendly Manufacturing. The findings and proposals of this paper can be a beginning step for Moroccan companies to completely use their capability of environmental practices and improve their manufacturing productivity performance while identifying trends in organizational development.

7

Improving work organisation in the production hall – a case study

Zasadzień Michał

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

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2020

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z. 147

327--350

EN

Purpose: The aim of the research was to assess the effectiveness of implementing Lean Manufacturing (One-Piece-Flow) elements in a company producing shock absorbers. Design/methodology/approach: With the help of VSM, the most important problem in the production process was diagnosed, and by using the 5 Whys tool, the root causes of the problems were identified. A simulation of introducing the One-Piece-Flow system into the production line was then used to estimate the most optimal solution. After choosing the solution, it was implemented, and the results obtained were verified. Findings: As a result of the conducted analyses, the most important problems related to planning, scheduling and the flow of intermediates were identified. The 5 Whys analysis allowed for the grouping of individual problems by common causes. Detailed solutions to the problems were proposed, which were included in the future Value Stream Map. Research limitations/implications: Conducting research in a working production process is limited and faces significant resistance from managers. Practical implications: The most important effects of implementing an improvement plan were minimising inventory from 138,062 units to 25,000 units, which reduced costs and indicates reduced waste. Lead time was limited to 9.67 days from 56.96 days. Originality/value: Research results confirm the effectiveness of introducing only some solutions of the Lean philosophy. This is particularly important if the enterprise is unable to comprehensively implement the Lean Manufacturing concept due to organisational or financial reasons.

8

Rynek amerykański. Dlaczego wciąż brakuje ręczników papierowych?

Graczyk Tomasz

Przegląd Papierniczy

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2020

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R. 76, nr 9

474--475

9

Application of the Philosophy of Management and Production Engineering in Eastern Asia in Improving the Processes of Urban Transport Operation

Wieczorek Andrzej, Madej Robert

Multidisciplinary Aspects of Production Engineering

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2020

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Vol. 3, Iss. 1

227--237

EN

The subject matter presented in the article touches the problem of incufficient efficiency of processes and systems in organisation. Achievement of adequate efficiency value is a guarantor of competitive advantage of enterprise. Therefore, it is necessary to constantly work on methods and techniques to improve efficiency, tailored to the needs of various organizations, which also includes service enterprises. Service enterprises include public transport companies. The purpose of the latter is to guarantee that the passenger will be transported from stop A to stop B within a certain time. Failure to achieve this goal incurs certain social costs. Therefore, the article focuses on measures and ways to improve efficiency, developed in Eastern Asian enterprises that have been successful as a result of their use. The first part of the article reviews the literature, including the methods used in this part of the world. The second part, however, concerns the possibility of using the BOST method in improving the efficiency of public transport enterprise processes in Poland.

10

Exploring critical success factors for the implementation of lean manufacturing in machinery and equipment SMEs

Yuik Chong Jia, Perumal Puvanasvaran A., Feng Chin Jeng

Engineering Management in Production and Services

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2020

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Vol. 12, no. 4

77--91

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.

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Zastosowanie wybranych narzędzi zarządzania jakością w celu zwiększenia efektywności maszyn w przedsiębiorstwie produkcyjnym

Greń Aleksandra, Zaziębło Paweł

Zarządzanie Przedsiębiorstwem

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2019

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Vol. 22, nr 3

11--18

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.

12

Lean implementation in Indian manufacturing MSMES: a SAP-LAP analysis

Matharu Misha, Sinha Neena

Management and Production Engineering Review

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2019

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Vol. 10, No. 1

68--78

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.

13

Does lean practices implementation impact on company performance? A meta-analytical research

Gonçalves Telma I. G., Sousa Paulo S. A., Moreira Maria R. A.

Management and Production Engineering Review

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2019

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Vol. 10, No. 4

11--24

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.

14

Wpływ implementacji szczupłego wytwarzania na wzrost sprzedaży przedsiębiorstwa

Łęgowik-Małolepsza M., Banaskiewicz N., Łęgowik-Świącik S.

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

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2018

|

z. 118

341--350

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.

15

Szczupłe wytwarzanie a wzrost sprzedaży jako kierunek realizacji strategii przedsiębiorstwa

Łęgowik-Małolepsza M., Baskiewicz N., Łęgowik-Świącik S.

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

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2018

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z. 130

405--416

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.

16

Improvement of implementation of the 5S method using the simplified FMEA method

Kawalec M., Pacana A., Rewilak J.

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

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2018

|

z. 119

139--150

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.

17

Barriers and opportunities in implementation of Lean Manufacturing tools in the ceramic industry

Kleszcz D.

Production Engineering Archives

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2018

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Vol. 19

48--52

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.

18

Example of Using Lean Manufacturing Tools in Assessing and Improving the Process of Car Arm Rest Production

Molenda M., Biernot A., Cierna H.

Multidisciplinary Aspects of Production Engineering

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2018

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Vol. 1, Iss. 1

217--222

EN

The paper deals with the use of Lean Manufacturing tools in improving the production process of car arm rests in a car manufacturing company in Poland. The article describes the original condition of a single production process of assembling ready pieces to produce car arm rests. The original condition was assessed and described with the use of some basic Lean indicators and value stream mapping. The aforementioned tools allowed to assess the process condition and to identify the organizational issues and their sources. It also enabled to reorganize the process and increase its efficiency. The further part of the article describes the results of improvement actions. The process assessment was held and improvements introduced in the first quarter of 2018.

19

Wireless technologies for lean manufacturing – a literature review

Gladysz B., Buczacki A.

Management and Production Engineering Review

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2018

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Vol. 9, No. 4

20--34

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].

20

Sustainable lean in SMEs: a quantitative analysis into improvement actions

Van Landeghem H., Claeys D., Van Landeghem T.

Management and Production Engineering Review

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2018

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Vol. 9, No. 4

10--19

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.