New Concept in Leanness Development and Assessment in Plant Life Cycle (PLC)

At the last decade of the 20 century, Womack et. Al introduced Lean concept to the industrial world. Since 1990 up to now, existed studies mostly have focused on lean production in the step of manufacturing, but in this research leanness concept has developed in the plant life cycle. In this paper leanness concept will be described as elimination of wastes in the phases of investment, plant design & construction(hardware), organization & systems design (software) and these three steps will be added to, elimination of previously described seven wastes in production step. For this purpose at first, the types of wastes in the above mentioned phases are defined by using Axiomatic Design methodology. After defining the types of wastes, a model for assessment of leanness is submitted. In this quantitative model, amount of leanness in each phase will be determined and combined to make a unique measure for total leanness. Dimensions of leanness are shown for quick understanding, by using a spider diagram. In the last section of the paper, the results of an example of the application of this model in fan industry are brought. This example shows the simplicity and powerfully of the model to determine the leanness in before production phases. © 2008 Authors all rights reserved.

[1]  Andy Neely,et al.  Performance measurement system design , 1995 .

[2]  Thane Morgan.  Lean manufacturing techniques applied to software development , 1998 .

[3]  John B. Kidd,et al.  Toyota Production System , 1993 .

[4]  P. Senge.  THE FIFTH DISCIPLINE , 1997 .

[5]  Brian H. Maskell,et al.  Performance Measurement for World Class Manufacturing: A Model for American Companies , 1991 .

[6]  Mark Lulgjuraj,et al.  Lean manufacturing at a tier-1 automotive supplier , 2000 .

[7]  Mark D. MacLean.  Implementing lean manufacturing in an automobile plant pilot project , 1996 .

[8]  P. Schroeder.  The Goal: A Process of Ongoing Improvement , 1994 .

[9]  Robert S. Kaplan,et al.  Measures for Manufacturing Excellence , 1990 .

[10]  Daniel Roos,et al.  The machine that changed the world : the story of lean production , 1991 .

[11]  Troy Hamilton.  A lean software engineering system for the Department of Defense , 1999 .

[12]  Joseph S. Kowalski.  An evaluation of the design of manufacturing measureables for the Ford production system , 1996 .

[13]  Marshall Goldsmith,et al.  The organization of the future , 1997 .

[14]  Steve Caplin,et al.  Principles Of Design , 2011 .

[15]  J. Cutcher-Gershenfeld,et al.  Lean Thinking , 2019, Encyclopedia of Sustainable Management.

[16]  Timothy D. Fry,et al.  Japanese manufacturing performance criteria , 1995 .

[17]  大野 耐一,et al.  Just-in-time for today and tomorrow , 1988 .

[18]  David J. Stec.  Performance measures for lean manufacturing , 1998 .

[19]  Dean A Sheppard.  The design of a lean automobile dismantling and recycling system , 1998 .

[20]  Hiromoto Toshiro.  Another hidden edge - Japanese management accounting , 2002 .

[21]  J. Temple Black,et al.  The design of the factory with a future , 1991 .

[22]  Robert A. Slack.  The application of lean principles to the military aerospace product development process , 1998 .

[23]  Matthew J. Matuszewski.  Implementation of lean manufacturing in a remote manufacturing facility , 1993 .

[24]  Jamie W. Flinchbaugh.  Implementing lean manufacturing through factory design , 1998 .

[25]  Dean H. Kropp,et al.  The New Manufacturing Challenge: Techniques for Continuous ImprovementThe New Manufacturing Challenge: Techniques for Continuous Improvement, by SuzakiKiyoshi. New York: Free Press, 1987, 270 pp., $24.95, cloth. , 1988 .

[26]  Auston Marmaduke Kilpatrick,et al.  Lean manufacturing principles : a comprehensive framework for improving production efficiency , 1997 .

[27]  洲崎 清,et al.  The new manufacturing challenge : techniques for continuous improvement , 1987 .

[28]  Steven R. Harman.  Implementation of lean manufacturing and one-piece flow at Allied Signal Aerospace , 1997 .