Background. The use of lean manufacturing systems in industrial enterprises reduces production losses and leads to a quality product at the lowest possible price. There are a number of problems that ...organizations face at the stage of implementing lean manufacturing tools, which not only slow down the process itself, but can also lead to the abandonment of further activities. Materials and methods. The article considers the development of an algorithm for the implementation of lean manufacturing projects in relation to the enterprise “Zavod GRAZ” JSC. The proposed algorithm includes two areas: training and education of personnel and diagnostics of activities and implementation of improvements in the enterprise. Results. It is shown that the algorithm is based on the established quantitative levels of a phased transition, which allow assessing the effectiveness of the process of implementing lean manufacturing improvements, as well as quickly adapting quality improvement processes for specific projects. Conclusions. The described method of performance evaluation allows you to evaluate not only the overall result, but also each individual event, which gives a clear picture of the reasons why the final goal was not achieved. The algorithm is universal and can be adapted to any enterprise.
Lean Production Systems are enterprise-specific, methodical frameworks for the continuous orientation of all enterprise processes to the customer in order to achieve overall objectives. Due to an ...increasing complexity of the digital transformation, the design of Lean Production Systems 4.0 is a challenging task for industrial engineering practice. For this, academia and industrial practice were analysed in a combined approach of a systematic literature review and a field study. The systematic literature review of 62 out of 1600 scientific papers shows that especially the tools, processes, and methods in Lean Production Systems are subject to digital transformation. By involving industrial practice in a field study, quantitative and qualitative insights were used to check scientific hypotheses and identify practical requirements by industrial engineers. As a result, 10 guidelines for the design of future Lean Production Systems 4.0 are derived. The practical implications of this paper enhance the evolution of enterprise-specific Lean Production System 4.0 frameworks.
Full text
Available for:
BFBNIB, GIS, IJS, KISLJ, NUK, PNG, UL, UM, UPUK
The energy-saving and emission reduction (ESER) strategy is a crucial measure for promoting the sustainability of manufacturing industry in green transition. Analyzing current practices and ...limitations of the ESER in the manufacturing industry, this paper proposes a new concept entitled lean energy-saving and emission-reduction (LESER) and an approach to effectively improve the energy efficiency and reduce waste emissions. This paper illustrates the definition of the LESER and establishes an implementation framework for LESER to improve the manufacturing process. To quantify and evaluate performance of LESER, the state space model of the carbon footprint for energy consumption and waste discharge is established. A method for implementing the LESER strategy is constructed in the following steps: (i) clarification of the current situation; (ii) analysis of the root cause; (iii) improvement; (iv) evaluation of the carbon emissions; (v) sustaining and standardizing. Finally, the LESER strategy is applied to the Zcrubber Group Co. Ltd., which is characterized with high pollution, high energy consumption, and high emission in green transition. Results demonstrate practicability of the proposed strategy to offer an effective measure for promoting sustainability of manufacturing industry.
Display omitted
•Proposing the LESER for promoting sustainability of manufacturing industry•Illustrating the concept and connotation of the LESER•Describing the carbon footprint for manufacturing process by state space model•Presenting the implementation processes of the LESER
Full text
Available for:
GEOZS, IJS, IMTLJ, KILJ, KISLJ, NLZOH, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UILJ, UL, UM, UPCLJ, UPUK, ZAGLJ, ZRSKP
This article discusses lean manufacturing methods aimed at improving the management of production processes in a chemical plant. The object of the study is the concept of lean production, the subject ...is the use of its methods in the production of low fission polyethylene in the public joint-stock company Kazanorgsintez. The article provides a brief overview of the methods and tools of lean manufacturing, which are most widely used in Russian industrial enterprises. Based on the example of low-density polyethylene production in Kazanorgsintez Public Joint-Stock Company, recommendations have been developed on the use of lean manufacturing methods to optimize production processes, in particular, the Just-inTime principle, which is implemented through the use of the automated KANBAN system (at the stage of production of low-density polyethylene) and the "pull" model (on the example of low-density polyethylene storage). As a result of the study, the prospects for the introduction of methods and tools of lean production at a chemical enterprise are shown.
•Slag is an engineering waste and by-product in the production of iron in a blast furnace.•AAS consists of alumina-silicates and silicates of lime; this makes it suitable for the production of ...geopolymers.•Slag is an excellent performance cementitious material, promoting to achieve higher compressive strength.•To examine the influences of GGBFS and AAS on the morphological characteristics of concrete.•To study the characteristic of high fineness GGBFS, to improve the microstructure property.
A single ton of ordinary Portland cement (OPC) demands around 4.0 G Joule energy and creates about a ton of CO2 emission. As part of our effort to preserve the environment, the incorporation of ground granulated blast-furnace slag (GGBFS) or fully replaced by alkali-activated slag (AAS) as an alternative binder to OPC. This concrete is environmental-friendly and also eases concerns in energy usage, raw material, and manufacturing cost for the traditional concrete. The cementitious properties of GGBFS and AAS promote their usage in the concrete matrix. Partial inclusion of slag for cement produces OPC or fully replaced by AAS is getting more attention as it is more pumpable, chemically stable, and resistant to an aggressive environment. This paper reviews the source, clean production and chemical compositions of the GGBFS and AAS. This literature review also objects to provide reviews on the properties, hardening conditions, and behaviors of GGBFS and AAS -based concrete composites as well as to synopsize the research development trends to generate comprehensive insights into the potential applications of GGBFS and AAS concrete as raw building materials for making sustainable and greener concrete composites, towards industrializing ecofriendly buildings today.
Full text
Available for:
GEOZS, IJS, IMTLJ, KILJ, KISLJ, NLZOH, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UILJ, UL, UM, UPCLJ, UPUK, ZAGLJ, ZRSKP
The adoption of Industry 4.0 technologies has been deemed as a strategy to increase product quality and make manufacturing processes more efficient. However, the way that these technologies are ...integrated into existing production systems and which processes they can support is still under investigation. Thus, this paper aims to examine the relationship between lean production (LP) practices and the implementation of Industry 4.0 in Brazilian manufacturing companies. To achieve that we use data from a survey carried out with 110 companies of different sizes and sectors, at different stages of LP implementation. Data collected were analysed by means of multivariate analysis. Our findings indicate that LP practices are positively associated with Industry 4.0 technologies and their concurrent implementation leads to larger performance improvements. Further, the contextual variables investigated do matter to this association, although not all aspects matter to the same extent and effect.
Full text
Available for:
BFBNIB, GIS, IJS, KISLJ, NUK, PNG, UL, UM, UPUK
The purpose of the paper is to study the features of the lean production implementation in the dairy industry of Ukraine. Methodology. To achieve the purpose and solve the tasks set in the paper, a ...system of general and special research methods was used, namely methods of scientific knowledge (scientific abstraction, analysis and synthesis, deduction, generalization) to study the theoretical principles of the lean production implementation in Ukraine’s enterprises, and questionnaire to assess the lean production implementation’s effectiveness in the enterprises of Ukraine’s dairy industry. Results of the survey examine the theoretical and methodological foundations of the “lean production” concept: taking into account all the definitions mentioned above, the following author’s definition of lean production is put forward: lean production is a system of the enterprise, which is constantly improving, aimed at building all processes in a continuous flow of value creation by preventing and eliminating all types of losses, involving staff in teamwork based on project approaches and maintaining safe working conditions in order to create attractive value for the consumer. Methodological support for rapid assessment of the lean production implementation’s effectiveness on the basis of employee surveys has been developed and the efficiency of the lean production implementation at the enterprises of Ukraine’s dairy industry has been assessed. It is concluded about the lack of effectiveness of implementing lean production at three enterprises of Ukraine’s dairy industry. This is due to the short period of the lean production implementation, as Enterprise 1 only started implementation at the end of 2020. Based on the survey and questionnaire of employees and managers of Ukraine’s dairy industry, the main stereotypes related to the implementation of lean production are identified and refuted, and the reasons for the slow and inefficient implementation of lean production are identified. Lean manufacturing cannot be implemented once and for all, it must be done constantly, because lean manufacturing is a tool for gaining a competitive advantage. Scientific novelty: methodological support for rapid assessment of the lean production implementation’s effectiveness has been further developed, which, unlike others, takes into account the peculiarities of the dairy industry and allows to determine problems and prospects for enterprise development on the basis of a questionnaire. A promising direction of research is a more detailed analysis of the “lean production polygon”, which is based on the survey. A more detailed analysis of the underlying three pentagons will reveal problems in the three subsystems of lean production.
In recent years, Industry 4.0 has emerged as one of the most discussed concepts and has gained significant popularity in both academia and the industrial sector. Both Industry 4.0 and lean ...manufacturing utilise decentralised control and aim to increase productivity and flexibility. However, there have been few studies investigating the link between these two domains. This article explores this novel area and maps the current literature. This is achieved through a systematic literature review methodology, investigating literature published up to and including August 2017. This article identifies four main research streams concerning the link between Industry 4.0 and lean manufacturing, and a research agenda for future studies is proposed.
Full text
Available for:
BFBNIB, GIS, IJS, KISLJ, NUK, PNG, UL, UM, UPUK
Purpose
The purpose of this paper is to examine the moderating role of Industry 4.0 technologies on the relationship between lean production (LP) and operational performance improvement within ...Brazil, a developing economy context.
Design/methodology/approach
One representative from each of the 147 studied manufacturing companies filled in a survey on three internally related lean practice bundles and two Industry 4.0 technology bundles, with safety, delivery, quality, productivity and inventory as performance indicators. As this study was grounded on the contingency theory, multivariate data analyses were performed, controlling for four contingencies.
Findings
Industry 4.0 moderates the effect of LP practices on operational performance improvement, but in different directions. Process-related technologies negatively moderate the effect of low setup practices on performance, whereas product/service-related technologies positively moderate the effect of flow practices on performance.
Originality/value
With the advent of Industry 4.0, companies have been channelling their efforts to achieve superior performance by advancing levels of automation and interconnectivity. Eventually, widespread and proven manufacturing approaches, like LP, will integrate such technologies which may, in turn, impair or favour operational performance. Contrary to previous studies, the contingencies appeared to have a less extensive effect. The authors point to various options for further study across different socio-economic contexts. This study evidenced that purely technological adoption will not lead to distinguished results. LP practices help in the installation of organisational habits and mindsets that favour systemic process improvements, supporting the design and control of manufacturers’ operations management towards the fourth industrial revolution era.
Companies use different production policies to ensure customer demands are satisfied in time. To track the performance of production policies some important Key Performance Indicators related to ...production control and management are On-Time Delivery (OTD), machine or line productivity (OEE - Overall Equipment Efficiency), optimization of inventory levels between workstations (WIP), customer satisfaction i.e. prioritization of customer orders according to requirements of the customer, and backlog minimization. In this study, a real-life production management problem is described, modelled, and solved to improve customer delivery rate and, to plan manufacturing orders using lean production tools. Currently, the Make-to-Stock policy is used for semi-finished materials. The problems encountered are low customer service level, high level of WIP between operations and efficiency losses. Therefore, the goal of this study is to increase efficiency (OTD, OEE, and customer satisfaction) by minimizing setup time, decreasing WIP by minimizing earliness, backlog quantity level and improving service level by minimizing lateness of orders. Since these goals contradict each other, we propose a multi-objective mathematical formulation with a setup carryover strategy. Then we formulate a Goal Programming (GP) model and solve it by using different GP variants and the normalization method. Finally, we discuss numerical results and provide our final remarks and conclusions.
Full text
Available for:
BFBNIB, GIS, IJS, KISLJ, NUK, PNG, UL, UM, UPUK
PDF
