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.
•Studied lean production and low-carbon management in remanufacturing systems.•Proposed decision-making method for lean low-carbon management.•Established functions to characterize carbon trail of ...remanufacturing production management.
Remanufacturing is one of the effective ways to achieve carbon peak and carbon neutralization. Additionally, lean remanufacturing plays an irreplaceable role in promoting a circular economy and industrial green development. This paper focuses on the application of lean production and low-carbon management in remanufacturing assembly systems. We propose an optimization decision-making method for lean low-carbon management for remanufacturing assembly. On the basis of the carbon footprint, we interpret and measure the quality, cost, and time of remanufacturing assembly systems. Functions are established to characterize the carbon trajectory of production management. Then, a low-carbon optimization model of remanufacturing assembly production management is constructed to minimize carbon emissions with combined sorting of parts, and a solution method based on a genetic algorithm, which has the attributes of excellent quality, low cost, and high efficiency, is studied. Interestingly, through practical application in engine regeneration enterprises, we have found that integrating lean and low-carbon approaches can enhance the total factor productivity of the remanufacturing assembly system. This study provides practitioners and decision-makers with an effective way to formulate lean low-carbon management of remanufacturing.
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.
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•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
•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.
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.
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.
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.
With the diffusion of Industry 4.0 technologies, firms can decentralize operational decisions, fostering a data-driven Digital Transformation (DT) across all organizational levels. Digitalized ...shopfloors can leverage an unprecedented availability of data for better and faster decision-making, resulting in enhanced operational performance. However, limited research has investigated the organizational and individual implications for those who run the manufacturing lines: production managers, supervisors, team leaders, and workers. By adopting a socio-technical framework, this study aims to disentangle the effects that digitalization has on shopfloors’ organizational structures, decision-making processes, and individual competencies, as well as the interdependencies among them. An exploratory approach was adopted, based on an empirical cross-country study involving 34 semi-structured interviews conducted in the Italian and Spanish automotive sectors. Analyzed through the lenses of information-processing, knowledge-based, and dynamic capability theories, our findings reveal through five propositions how digitalization induces a “polarization” of operational decision-making: shopfloors are run by knowledgeable data-empowered production managers and autonomous information-processing team leaders on the front line, with a reduced importance of supervisors. Upskilling needs appear for team leaders but not production workers, whose involvement, however, emerges as a key factor for a successful digitalization and overall performance in initial DT stages. This study contributes to literature on digitalization by exposing managerial tensions and dynamic capabilities, along with a deeper understanding of the micro-foundations of DT in terms of implications for shop-floor decision-makers. Managerial implications are directed at creating awareness about the centrality of production team leaders, and future research avenues are proposed.
The objective of this research is to identify critical success factors (CSFs) of the reusable plastic packaging (RPP) system and to establish their interrelationship in the context of manufacturing ...industries. Fourteen CSFs were shortlisted by reviewing the literature and considering expert team inputs. To explore the mutual influence between the identified CSFs the Interpretive Structural Modeling (ISM) approach was applied. To strengthen link interpretation, ISM methodology was supported by the Total Interpretive Structural Modeling (TISM) approach. Further, to identify the factors with high driving power the Matrice d’Impacts Croisés Multiplication Appliqués à un Classement (MICMAC) analysis was employed. It was concluded that three CSFs namely, ‘top management commitment’ ‘lean support,’ and ‘optimized inventory management’ were the critical ones with high influential power. This study aims to help the decision-makers in developing effective strategies for the implementation of the RPP system in the case sector for achieving sustainability.
•The critical success factors (CSFs) of reusable plastic packaging were identified.•The TISM approach was used for establishing the interrelationship between the CSFs.•The MICMAC analysis was used to identify CSFs have high driving power.•A CSF namely ‘Top management commitment’ was found to be the most significant.
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