
Lean Manufacturing: Implementation, Opportunities and Challenges
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Content
- Intro
- Contents
- Foreword
- Acknowledgments
- Chapter 1
- Lean Thinking across the Company: Successful Cases in the Manufacturing Industry
- Abstract
- 1. Introduction
- 2. Theoretical Background
- 2.1. Value-Added Activities and Wastes
- 2.2. Some Lean Methods and Tools
- 2.3. Lean Applied across the Company
- 2.3.1. About Lean in Logistics
- 2.3.2. About Lean in Information Flows
- 2.3.3. About Lean in Ergonomics
- 3. Case Studies Showing Lean Applied across the Company
- 3.1. Introduction and Companies' Contextualization
- 3.2. Cases of Lean Applied to Logistics and Production
- 3.2.1. The Case of Company A
- 3.2.2. The Case of Company B
- 3.2.3. The Case of Company C
- 3.2.4. The Case of Company D
- 3.3. Cases of Lean Applied to Information Flow
- 3.3.1. The Case of Company E
- 3.3.2. The Case of Company F
- 3.3.3. The Case of Company G
- 3.4. Cases of Lean Applied to Ergonomics
- 3.4.1. The Case of Company H.1
- 3.4.2. The case of Company H.2
- 3.4.3. The Case of Company I
- Conclusion and Future Work
- Acknowledgments
- References
- Chapter 2
- From the Factory Floor to New Product Development: Development and Implementation of a Lean Assessment Tool
- Abstract
- 1. Introduction
- 2. Theory: Lean in the Perspective of New Product Development Fundamentals
- 2.1. Some Definitions of Innovation, Product Development and Value
- 2.2. Some Fundamental Differences between Manufacturing and NPD
- 2.3. Lean from the Manufacturing Floor to the Product Developer's Desk
- 2.4. Comparison of Traditional PD and Lean PD
- 3. A Lean Product Development Model
- 4. A Lean Maturity Assessment Tool: Process and Structure
- 5. Case Study: The Impact of Business Context on LPD Gap Identifications
- 5.1. Contextual PD Dimensions
- 5.2. Results from Assessment
- Conclusion
- References
- Chapter 3
- Benefits and Challenges of Lean Manufacturing in Make-to-Order Systems
- Abstract
- 1. Introduction
- 1.1. Background: Lean Manufacturing in MTO Systems
- 2. Labour Flexibility: Benefits and Challenges
- 2.1. Case System 1: Assembly Line
- 2.2. Case System 2: A Job Shop
- 2.3. Certain Models at Certain Workstations
- 2.4. Any Model at Certain Workstations
- 2.5. Certain Models at Any Workstation
- 2.6. Any Model at Any Workstation
- 3. Manufacturing System Flexibility: Benefits and Challenges
- 3.1. Dedicated Machine Systems
- 3.2. Flexible Manufacturing Systems
- 3.3. Reconfigurable Manufacturing Systems
- 3.4. Manufacturing System Layout
- 4. Current Implications for Lean Manufacturing in Make-to-Order Systems
- 4.1. Outlook: Impact of Industry 4.0 and Other Evolving Technologies
- Conclusion
- References
- Chapter 4
- Sustaining Lean in Organizations through the Management of Tensions and Paradoxes
- Abstract
- 1. Introduction
- 2. Types of Organizational Paradoxes
- 3. The Management of Organizational Paradoxes
- 4. Case 1. The Financial Company (Denmark)
- 4.1. The Organizing Paradox
- 4.2. The Belonging Paradox
- 5. Case 2. The Cancer Department at a University Hospital
- 5.1. The Organizing Paradox
- 5.2. The Performing Paradox
- 6. Case 3. The Garment Manufacturer in Bangladesh
- 6.1. Learning Paradox
- 6.2. Performing Paradox
- Conclusion and Recommendations
- References
- Chapter 5
- The Impact of 5S + 1S Methodology on Occupational Health and Safety
- Abstract
- 1. Introduction
- 2. Occupational Safety
- 2.1. Hazards and Risks
- 2.2. Risk Assessment
- 2.3. Industrial Vehicles
- 3. Lean Thinking
- 3.1. 5S
- 3.2. 6S
- 4. Research Methodology
- 5. Case Study
- 5.1. Initial State
- 5.1.1. Sorting Space Safety
- 5.1.2. 5S Implementation
- 5.2. The Impact of 5S on Safety
- Conclusion
- References
- Chapter 6
- Value of Real-Time Data for Cycle Time Optimisation at Wet Tools
- Abstract
- 1. Introduction
- 1.1. Organisation of the Chapter
- 2. Literature Review
- 3. Wet Station Description
- 4. System Modelling
- 4.1. Model Validation
- 5. Assignment Strategies
- 6. Preliminary Findings
- 7. Assignment Strategies Generalisation to More Complex Scenarios
- 8. Results
- 9. Discussion
- Conclusion
- Acknowledgments
- References
- Chapter 7
- The Eighth Waste: Non-Utilized Talent
- Abstract
- 1. Introduction
- 1.1. Background
- 2. Methodology
- 3. Results
- 3.1. Rewards
- 3.2. Recognition
- 3.3. Justice
- 3.4. Motivation
- 3.5. Training and Knowledge
- 3.6. Goals
- 3.7. Evaluation Feedback
- 3.8. Self-Esteem
- 3.9. Resources
- 3.10. Assessment of the Eighth Waste
- Conclusion
- References
- Chapter 8
- Quality and Safety Continuous Improvement through Lean Tools
- Abstract
- 1. Introduction
- 2. Case Study
- 2.1. Presentation of One Company Situation
- 3. The Use of Lean Tools
- 3.1. Value Stream Mapping
- 3.2. A3 - Problem Solving
- 3.3. Daily Kaizen
- 3.4. 5S
- 3.5. Standard Work
- 3.6. On Point Lesson (OPL)
- 3.7. Visual Management
- 3.8. Andon
- 3.9. Heijunka
- 3.10. Kanbans
- 3.11. Jidoka
- 3.12. Poka-Yoke
- 3.13. Milkrun
- 3.14. Overall Equipment Effectiveness (OEE)
- 3.15. Single-Minute Exchange of Die (SMED)
- 3.16. Yokoten
- 3.17. Total Productive Maintenance (TPM)
- 4. TPM and a Connected Industry (Industry 4.0)
- 5. Quality Continuous Improvement - Leading Excellence with TQM and IMS
- 6. Lean Safety - Integrating Lean Production with Safety Management
- Conclusion
- Acknowledgments
- References
- Chapter 9
- Lean Manufacturing Applied to the Production and Assembly Lines of Complex Automotive Parts
- Abstract
- 1. Introduction to Automotive Industry
- 1.1. The Global Context of the Automotive Industry
- 1.2. The Importance of the Automotive Sector in World Economy
- 2. The Manufacture of Components for the Automotive Industry
- 3. Command Cables for Car Vehicles
- 3.1. The Makeup of Command Cables
- 4. Problems and Waste
- 5. Best Lean Tools Devoted to Component Production for the Automotive Industry
- 5.1. Kaizen
- 5.2. VSM
- 5.3. Visual Management
- 5.4. 5S
- 5.5. Standard Work
- 5.6. SMED
- 5.7. PDCA
- 6. Case Study
- 6.1. Definition of the Product
- 6.2. Definition of the lines
- 6.3. Problems and Wastes Identification
- 6.4. Methodology
- 6.5. Applying Lean Tools
- 6.6. Results and Critical Analysis
- Conclusion
- Suggestions for Future Work
- References
- Chapter 10
- SMED Applied to Composed Cork Stoppers
- Abstract
- 1. Introduction
- 2. Cork
- 2.1. Cork as a Natural Material
- 2.2. Cork Stoppers Industry
- 2.3. Types of Cork Stoppers
- 2.4. Composed Stoppers
- 3. Composed Stoppers Manufacturing Process
- 3.1. Work-Flow
- 3.2. Equipment
- 4. The Problem and the Challenge
- 4.1. Wastes Identification Trough VSM Tool
- 4.2. A3 Report
- 4.3. Internal and External Tasks
- 4.4. Equipment Improvements
- 5. Measuring the Benefits
- 6. Start of OEE Calculation
- Conclusion
- References
- Chapter 11
- Lean Production in the Portuguese Textile and Clothing Industry: The Extent of Its Implementation and Role
- Abstract
- 1. Introduction
- 2. Context Study
- 3. Literature Review
- 4. Research Methodology
- 4.1. Questionnaire Design and Implementation
- 4.1.1. Target Population
- 4.1.2. Design, Validation, and Distribution Methodology
- 4.1.3. Objectives of the Main Parts and Sections
- 4.2. Interviews Preparation and Implementation
- 5. Results, Analysis, and Discussion
- 5.1. Questionnaire Results and Discussion
- 5.1.1. Companies' Production Models
- 5.1.2. Awareness of LP and Related Concepts and Tools
- 5.1.3. LP Implementation and Implementation Process
- 5.1.4. Satisfaction Level and Understanding of LP
- 5.2. Follow-Up Interviews Results and Discussion
- 5.3. Discussion and Limitations
- Conclusion
- References
- Chapter 12
- Lean Manufacturing Applied to a Complex Electronic Assembly Line
- Abstract
- 1. Introduction
- 2. Literature Review
- 2.1. Value Stream Mapping (VSM)
- 2.2. Lean Line Design (LLD)
- 2.3. Balancing Line
- 2.4. Single Minute Exchange of Die (Quick Changeover)
- 2.5. DMAIC (Define, Measure, Analyse, Improve and Control)
- 3. Methodology
- 4. Case Study - Current State
- 4.1. Applying Value Stream Mapping (VSM) to Define the Current State
- 4.2. Using Lean Line Design (LLD) to Describe the Current State
- 4.2.1. Current State
- 4.2.1.1. Man
- 4.2.1.2. Machine
- 4.2.1.3. Method
- 4.2.1.4. Environment
- 4.2.1.5. Layout Analysis
- 4.2.1.6. Line Balancing Process Analysis
- 4.2.2. Production Process Optimization
- 4.2.2.1. Assembly Fixtures
- 4.2.2.2. Workstation 01 - Pan Motor Preparation
- 4.2.2.3. Workstation 02 - Tilt Motor Preparation
- 4.2.2.4. Workstation 03 - Wiper Motor Preparation
- 4.2.2.5. Workstation 04 - Pan Stage I Assembly
- 4.2.2.6. Workstation 05 - Pan Stage II Assembly
- 4.2.2.7. Workstation 07 - Tilt Center I Assembly
- 4.2.2.8. Workstation 08 - Tilt Center II Assembly
- 4.2.2.9. Workstation 09 - Camera Module Assembly
- 4.2.2.10. Workstation 10 - Front Shell Assembly
- 4.2.2.11. Workstation 11 - Rear Shell Assembly
- 4.2.2.12. Workstation 12 - Final Assembly
- 4.2.2.13. Workstation 15 - Leak Test
- 4.3. Results and Discussion about the Current State
- 5. Case Study - Improving Solutions
- 5.1. Applying Lean Line Design (LLD)
- 5.1.1. Improvement Solutions
- 5.1.1.1. First Scenario
- 5.1.1.2. Second Scenario
- 5.1.1.3. Third Scenario
- 5.1.1.4. Fourth Scenario
- Properties Collection of Layouts Purpose
- Attributes Table
- Matrix Selection Method
- 5.2. Production Process Optimization
- 5.2.1. Man
- 5.2.2. Machine
- 5.2.3. Method
- 5.2.4. Environment
- 5.3. Improvements Solutions
- 5.3.1. Assembly Fixtures Improvement
- 5.3.1.1. Workstation 01 - Pan Motor Preparation
- 5.3.1.2. Workstation 02 - Tilt Motor Preparation
- 5.3.1.3. Workstation 03 - Wiper Motor Preparation
- 5.3.1.4. Workstation 04 - Pan Stage I Assembly
- 5.3.1.5. Workstation 05 - Pan Stage II Assembly
- 5.3.1.6. Workstation 07 - Tilt Center I Assembly
- 5.3.1.7. Workstation 08 - Tilt Center II Assembly
- 5.3.1.8. Workstation 09 - Camera Module Assembly
- 5.3.1.9. Workstation 10 - Front Shell Assembly
- 5.3.1.10. Workstation 11 - Rear Shell Assembly
- 5.3.1.11. Workstation 12 - Final Assembly
- 5.3.1.12. Workstation 15 - Leak Test
- 6. Results and Discussion
- 6.1. Results and Discussion of the LLD Implementation
- 6.2. Conclusion and Discussion Production Process Optimization
- Conclusion
- References
- Chapter 13
- Karakuri: The Application of Lean Thinking in Low-Cost Automation
- Abstract
- 1. Principles of Lean Production
- 2. Principle of Produce only According to Demand
- 3. Produce on Demand
- 4. Pull System Method
- 4.1. ABC/XYZ Analysis
- 4.2. Just in Time
- 4.3. Kanban
- 4.4. Milk Run
- 4.5. Supermarkets
- 4.6. Vendor Managed Inventory
- 4.7. Karakuri
- 5. Karakuri Technique
- 6. Physics - Mechanical Structures Designed with Simplicity
- 6.1. Inclined Plane
- 6.2. Levers
- 7. Ergonomic Aspects
- 8. Internal Logistics and the Handling of Materials
- 8.1. Productivity
- 8.2. Kaizen Tool
- 9. Karakuri Concepts in Lean Internal Logistics
- 10. Advantages of Karakuri Application
- Conclusion
- References
- Chapter 14
- Lean and Ergonomics: How to Increase the Productivity Improving the Wellbeing of the Workers - A Case Study
- Abstract
- 1. Introduction
- 2. Problem Description
- 2.1. Products: General Description
- 2.2. Products: Specifications
- 2.2.1. Radiators M and H
- 2.3. Integrus (Case/Cabinet)
- 3. Methodology
- 4. Brainstorming
- 5. Ideas Implementation
- 5.1. Radiators
- 5.1.1. Supply
- 5.1.2. Encasing
- 5.1.3. Testing
- 5.1.4. Packing
- 5.1.5. Loading the Supply Car
- 5.2. Integrus Case
- 5.2.1. Unloading the Case onto the Electric Scissor Lifter
- 5.2.2. Textplate/Chargers Assemble
- 5.2.3. Testing
- 5.2.4. Loading the Supply Car
- 5.3. Integrus Cabinet
- 5.3.1. Unloading the Case onto the Electric Scissor Lifter
- 5.3.2. Textplate/Chargers Assemble
- 5.3.3. Testing
- 5.3.4. Loading the Supply Car
- 5.4. DDI
- 6. Results and Discussion
- Conclusion
- References
- Chapter 15
- Measurement of the Level of Implementation of Sociotechnical and Ergonomic Practices and Lean Production Practices: Considerations from a Systematic Review Process
- Abstract
- 1. Introduction
- 2. Methodological Procedures
- 2.1. Methodological Framework
- 2.2. Knowledge Development Process - Construtivist (Proknow-C)
- 2.3. Procedures for Collecting and Analyzing Data
- 2.4. Bibliometric Analysis of the Bibliographic Portfolio (BP)
- 2.5. Systemic Analysis of the Articles in the Bibliographic Portfolio
- 3. Results
- 3.1. PB Bibliometric Analysis
- 3.2. PB Systemic Analysis - Constitutive and Operational Definitions
- 3.2.1. Elements that Compose the Construct for Lean Production Practices (LP)
- 3.2.2 Elements of the Construct for Sociotechnical and Ergonomic Practices (SE)
- 4. Final Remarks
- Appendix A- Bibliographic Portfolio - PB
- References
- Chapter 16
- Lean Manufacturing and Industry 4.0: Facing New Challenges from a Shop-Floor Perspective
- Abstract
- 1. Objectives of This Chapter
- 2. Operational Excellence and Lean Manufacturing: From Japanese Origins to the American Reinterpretation
- 3. Evolution of Lean Manufacturing and Today's Main Challenges
- 4. Information Technology as a Driver of Change
- 5. Cleaner Technologies as a Driver of Change
- 6. Final Reflections
- References
- Chapter 17
- Lean Healthcare in a Cancer Chemotherapy Unit: Implementation and Results
- Abstract
- 1. Introduction
- 2. Literature Review
- 2.1. Lean Healthcare: Fundamental Concepts
- 2.2. The Literature Related to Lean Healthcare
- 3. The Implementation of Lean Healthcare in the Studied Hospital
- 3.1. The Implementation Method
- 3.2. The Studied Hospital
- 3.3. Description of the Implementation Phases
- 3.3.1. Phase 1: Defining the Scope
- 3.3.2. Phase 2: Measuring and Mapping the Initial Situation
- 3.3.3. Phase 3: Analyzing the Current Situation and Developing the Future Situation
- 3.3.4. Phase 4: Implementing the Future Situation
- 3.3.4.1. Kaizen in the APAC Information Stream
- 3.3.4.2. Kaizen in the Blood Exams
- 3.3.4.3. Kaizen in Triage (SIGA and Indications)
- 3.3.4.4. Kaizen in Chemotherapy
- 3.3.5. Phase 5: Controlling the Process
- Conclusion
- References
- About the Editors
- Index
- Blank Page
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