study on implementation of lean principles in a small scale enterprises
S.PRABHUTHIRUMOORTHY,K.V.POORNACHANDRAN,R.PARAMESHWARAN
Published in International Journal of Advanced Research in Mechanical and Production Engineering and Development
ISSN: 2320-7256 Impact Factor:1.398 Volume:1 Issue:2 Year: 08 April,2014 Pages:63-95
Abstract
Lean principles are being implemented both in large and small scale manufacturing enterprises. They are not much effective in implementing lean principles due to lack of knowledge and skills as said by previous authors. There are various lean tools such as Value Stream Mapping (VSM), Kanban and SMED, Optimization tools such as FUZZY LOGIC, QFD and FMEA are used to lean principles and to measure the performance in manufacturing enterprises. This research has explore the participation of lean and optimization tools with regard to lean implementation. It has been noted that not many articles revealed the combination of both tools. This paper discuss the applicability of these models for the effectiveness of lean implementation in small manufacturing enterprises. 1*
Kewords
VSM, SMED, Kanban, FUZZY, FMEA, QFD
Reference
1) Rosnah MY, Othman A – Lean Manufacturing Implementation in a Plastic Moulding Industry,AUT University (2012) 2) A.R. Rahani, Muhammad al-Ashraf – Production Flow Analysis through Value Stream Mapping: A Lean Manufacturing Process Case Study, Procedia Engineering 41 (2012) 1727 - 1734 3) Kuhlang, P., T. Edtmayr, and W. Sihn(2011) 'Methodical approach to increase productivity and reduce lead time in assembly and production-logistic processes', CIRP Journal of Manufacturing Science and Technology, Vol.4.No.1, pp. 24-32. 4) Lian, Y.-H. and H. Van Landeghem(2002) 'An application of simulation and value stream mapping in lean manufacturing'. CIRP Journal of Manufacturing Science and Technology, Vol.No.1, pp. 35-47. 5) Fawaz A. Abdulmalek, JayantRajgopal – Analyzing the benefits of lean manufacturing and value stream mapping via simulation: A process sector case study, International Journal of Production Economics 107 (2007) 223-236 6) Yang, Y.Q., Shod Qing Wang.,( 2003) 'A fuzzy quality function deployment system for buildable design decision-makings', Automation in Construction,. Vol.No.4, pp. 381-393. 7) Almannai, B., R. Greenough, and J. Kay (2008) 'A decision support tool based on QFD and FMEA for the selection of manufacturing automation technologies', Robotics and Computer-Integrated Manufacturing,Vol.No.4 pp. 501-507. 8) Hu-Chen Liu, Long Liu, Qi-HaoBian, Qin-Lian,Na Dong, Peng-Cheng Xu – Failure mode and effect analysis using fuzzy evidential reasoning approach and grey theory, Expert systems with Applications 38 (2011) 4403-4415 9) N.C. Tsourveloudis, E. Dretoulakis, S. Ioannidis – Fuzzy work-in-process inventory control of unreliable manufacturing systems, Information sciences 127 (2000) 69-83 10) Jesus Gonzalez, Ignacio Rojas, Hector pormares, Luis J. Herrera, Alberto Guillen, Jose M.Pallomares, Fernando Rojas – Improving the accuracy while preserving the interpretability of fuzzy function approximators by means of multi-objective evolutionary algorithms, International Journal of Approximate Reasoning 44 (2007) 32-44 11) FarzadBehrouzi, Kuan Yew Wong - Lean performance evaluation of manufacturing systems: A dynamic and innovative approach, Procedia Computer Science 3 (2011) 388- 395 12) Christian Hofer, CuneytEroglu, Adriana Rossiter Hofer – The effect of lean production on financial performance: The mediating role of inventory leanness, International journal of Production Economics 138 (2012) 242-253 13) Rosemary R. Fullerton, Cheryl S. Mc Watters – The production performance benefits from JIT implementation, Journal Operations Management 19(2001) 81-96 14) Matthias Holweg – The genealogy of lean production, Journal of Operations Management 25(2007) 420-437 15) Yoshiki Matsui – An empirical analysis of just-in-time production in Japanese manufacturing companies, International Journal Production Economics 108 (2007) 153- 164 16) Mihai apreutesei, E.( 2010) ' Lean Manufacturing-A Powerful Tool for reducing waste during the process. ANALELE UNIVERSITAT Vol.No.5,pp. 23-34. 17) Gautam, N. and N. Singh(2008)'Lean product development: Maximizing the customer perceived value through design change (redesign)', International Journal of Production Economics, Vol.No.1, pp. 313-332. 18) Diego Fernando, M.D. and L. Rivera Cadavid(2007)'Lean manufacturing measurement: the relationship between lean activities and lean metrics', Estudios Gerenciales, Vol.No.5, pp. 69-83. 19) Pool, A., J. Wijngaard, and D.-J. van der Zee(2011) 'Lean planning in the semi-process industry, a case study', International Journal of Production Economics, Vol.No.5,pp 194- 203. 20) Sullivan, W.G., T.N. McDonald, and E.M. Van Aken,( 2002) 'Equipment replacement decisions and lean manufacturing. Robotics and Computer-Integrated Manufacturing,Vol.No.3,pp. 255-265. 21) Wang, P., Treville, S.d.,( 2009) 'Flow production of pipe spool fabrication: Simulation to support implementation of lean technique', Journal of Construction Engineering and Management,.Vol.No.10,pp. 1027-1038. 22) Almomani, M. Ahmad Mumani,(2013) 'A proposed approach for setup time reduction through integrating conventional SMED method with multiple criteria decision-making techniques', Computers & Industrial Engineering, Vol.No.4, pp. 461-469. 23) Bakri, A.H., Abdul Rahman Abdul Rahim (2012) 'Boosting Lean Production via TPM. Procedia - Social and Behavioral Sciences, Vol. 4,pp. 485-491. 24) Bicheno, J., M. Holweg, and J. Niessmann(2001)'Constraint batch sizing in a lean environment.',International Journal of Production Economics, Vol.No.1), pp. 41-49. 25) Ahmad, M.F, Zakuan, N., (2012) 'Relationship of TQM and Business Performance with Mediators of SPC, Lean Production and TPM', Procedia - Social and Behavioral Sciences, Vol.No.5, pp. 186-191 26) Sanjay Bhasin – Performance of Lean in Large organisations, journal of manufacturing systems 31 (2012) 349-357 27) Krisztina Demeter, ZsoltMatyusz – The impact of lean practices on inventory turnover, International Journal Production Economics 133 (2011) 154-163 28) Ma Ga (Mark) Yang, Paul Hong, Sachin B. Modi – Impact of lean manufacturing and environmental management on business performance: An empirical study of manufacturing firms, International Journal Production Economics 129 (2011) 251-261 29) NitinUpadhye , S.G. Deshmukh, Suresh Garg – Lean manufacturing system for medium size manufacturing enterprises: an Indian case, International Journal of Management Science and Engineering Management 5 (2010) 362-375 30) David J. Meade, Sameer Kumar, AbdolazimHoushyar – Financial Analysis of a Theoretical Lean Manufacturing Implementation using Hybrid Simulation Modelling, Journal of manufacturing systems (2006) 31) Danny J. Johnson – A Framework for Reducing Manufacturing Throughput Time, Journal of manufacturing systems (2003) 32) S SMahapatra, S R Mohanty – Lean manufacturing in continuous process industry: An empirical study, Journal of Scientific and Industrial Research (2007) 19-27 33) T.Melton – The Benefits of Lean Manufacturing, Chemical Engineering Research and design 83(A6) 662-673 34) NoraniNordin, Baba Md Deros and Dzuraidah Abd Wahad – A survey on Lean Manufacturing Implementation in Malaysian Automotive Industry, International Journal of Innovation, Management and Technology ,October (2010) 35) R.Carvalho, A. Alves and I. Lopes – Principles and Practices of Lean Production applied in a Metal structures Production System. Proceeding of the world congress on Engineering, 2011 36) Abhishek kumarsingh, Rahul Singh Sisodhiya, RakeshBisht, AnkurMaheshwari – Use of Information System and lean manufacturing to reduce the waste in the process industry, International Journal of Electronics and Computer Science Engineering 778-786 37) HudliMohd .Rameez, K.H.Inamdar – Areas of Lean Manufacturing for Productivity Improvement in a Manufacturing Unit, World Academy of Science, Engineering and Technology 45(2010) 38) Adnan Hj. Bakri,Abdul Rahman Abdul Rahim,NoordinMohd. Yusof, Ramli Ahmad - Boosting Lean Production via TPM,International Congress on Interdisciplinary Business and Social Sciences 2012 485-491 39) Treville, S.d. and J. Antonakis,(2006) 'Could lean production job design be intrinsically motivating? Contextual, configurational, and levels-of-analysis issues', Journal of Operations Management, Vol.No.2, pp. 99-123. 40) Hofer, C., C. Eroglu, and A. Rossiter Hofer(2012) 'The effect of lean production on financial performance: The mediating role of inventory leanness. International Journal of Production Economics,' Vol.No.2, pp. 242-253. 41) Bhasin, S., Sanjay Bhasin,(2012)' Performance of Lean in large organisations', Journal of Manufacturing Systems, Vol.No.3, pp. 349-357. 42) Rubio, S. and A. Corominas(2008) 'Optimal manufacturing–remanufacturing policies in a lean production environment',Computers & Industrial Engineering, 2008,Vol.No.55, pp. 234-242. 43) Demeter, K. and Z. Matyusz(2011) 'The impact of lean practices on inventory turnover. International Journal of Production Economics,' Vol.No.3, pp. 154-163. 44) Fullerton, R.R., F.A. Kennedy, and S.K. Widener(2013)' Management accounting and control practices in a lean manufacturing environment. Accounting,' Organizations and Society, Vol.No.1, pp. 50-71. 45) Chandraiah Mopuru, Y.D.k., V.Sreenivasulu,P.Divakara Rao, Dr.C.Udaya Kiran(2013)' Implementation of Lean Manufacturing System on Oil Pump', International Journal of Innovations in Engineering and Technology (IJIET), Vol.No.1, pp. 441-451. 46) Goss, R., LJan Roth (2010) 'Leveraging new SEMI standard to reduce waste and improve flow for semicoductor manufacturing. Robotics and Computer-Integrated Manufacturing,'Vol.No.6, pp. 658-664.
