A new vision of LARG Manufacturing — A trail towards Industry 4.0

Abstract In the modern world, it is imperative to apply the concepts of Lean, Agile, Resilient and Green, collectively known as LARG Manufacturing to achieve business excellence. The objective of this study is to explore the possibility of collaboration between constituents of LARG Manufacturing with the facets of Industry-4.0. In this context, a thorough systematic literature review has been conducted to validate the research gap regarding integration of LARG Manufacturing with Industry 4.0. The study revealed that LARG constituent practices can be amalgamated with various facets of Industry-4.0 to provide operational, economic and environmental benefits. The increased process visibility, elimination of wastes, fast processes, high level of responsiveness to disruptions and eco-friendly manufacturing are the salient features of the LARG Manufacturing & Industry-4.0 synergy, fuelled by automation and BigData. In future, a comprehensive technology integrated implementation framework can be developed that employs LARG constituents with Industry-4.0 or Artificial Intelligence to achieve sustainability.

[1]  Layek Abdel-Malek,et al.  Design and implementation of flexible manufacturing solutions in agile enterprises , 2000 .

[2]  Malte Brettel,et al.  How Virtualization, Decentralization and Network Building Change the Manufacturing Landscape: An Industry 4.0 Perspective , 2014 .

[3]  Veres Cristina,et al.  The contribution of lean manufacturing tools to changeover time decrease in the pharmaceutical industry. A SMED project , 2018 .

[4]  Angappa Gunasekaran,et al.  Lean manufacturing in Brazilian small and medium enterprises: implementation and effect on performance , 2016 .

[5]  D. Towill,et al.  Supply chain migration from lean and functional to agile and customised , 2000 .

[6]  Ali Azadeh,et al.  Performance optimization of integrated resilience engineering and lean production principles , 2017, Expert Syst. Appl..

[7]  Artur Swierczek,et al.  The agile capabilities of Polish companies in the supply chain: An empirical study , 2009 .

[8]  Lifeng Zhou,et al.  Industry 4.0: Towards future industrial opportunities and challenges , 2015, 2015 12th International Conference on Fuzzy Systems and Knowledge Discovery (FSKD).

[9]  Matthias U. Heinicke,et al.  Framework for Resilient Production Systems , 2014, APMS.

[10]  S. N. Musa,et al.  Drivers and barriers analysis for green manufacturing practices in Malaysian smes: A preliminary findings , 2015 .

[11]  Jayant Rajgopal,et al.  Analyzing the benefits of lean manufacturing and value stream mapping via simulation: A process sector case study , 2007 .

[12]  Virgilio Cruz-Machado,et al.  Integration of Lean, Agile, Resilient and Green Paradigms in a Business Model Perspective: Theoretical Foundations , 2016 .

[13]  Vasdev Malhotra,et al.  A framework to enhance agile manufacturing system , 2017 .

[14]  Danny Berry,et al.  Leagility: Integrating the lean and agile manufacturing paradigms in the total supply chain , 1999 .

[15]  P. Baker.  The design and operation of distribution centres within agile supply chains , 2008 .

[16]  Yao Hu,et al.  Towards modeling of resilience dynamics in manufacturing enterprises: Literature review and problem formulation , 2008, 2008 IEEE International Conference on Automation Science and Engineering.

[17]  S. G. Deshmukh,et al.  Managing green productivity: Some strategic directions , 1998 .

[18]  Rambabu Kodali,et al.  A critical review of lean supply chain management frameworks: proposed framework , 2015 .

[19]  Khalil Elnamrouty,et al.  Seven wastes elimination targeted by lean manufacturing case study “gaza strip manufacturing firms’’ , 2013 .

[20]  Vasja Roblek,et al.  A Complex View of Industry 4.0 , 2016 .

[21]  Andreas Schumacher,et al.  A Maturity Model for Assessing Industry 4.0 Readiness and Maturity of Manufacturing Enterprises , 2016 .

[22]  Khamdi Mubarok,et al.  Smart manufacturing systems for Industry 4.0: Conceptual framework, scenarios, and future perspectives , 2018, Frontiers of Mechanical Engineering.

[23]  Riza Sulaiman,et al.  A Conceptual Model of Lean Manufacturing Dimensions , 2013 .

[24]  Detlef Zühlke,et al.  Towards a lean automation interface for workstations , 2017, Int. J. Prod. Res..

[25]  F BabiceanuRadu,et al.  Big Data and virtualization for manufacturing cyber-physical systems , 2016 .

[26]  Mohd Nizam Ab Rahman,et al.  A systematic literature review of internal capabilities for enhancing eco-innovation performance of manufacturing firms , 2019, Journal of Cleaner Production.

[27]  Joseph Sarkis.  A STRATEGIC DECISION FRAMEWORK FOR GREEN SUPPLY CHAIN MANAGEMENT , 2003 .

[28]  Michael Sony,et al.  Industry 4.0 and lean management: a proposed integration model and research propositions , 2018 .

[29]  Markus Biehl,et al.  International supply chain agility ‐ Tradeoffs between flexibility and uncertainty , 2001 .

[30]  Bülent Sezen,et al.  Effects of Green Manufacturing and Eco-innovation on Sustainability Performance☆ , 2013 .

[31]  Nuri Özgür Doğan,et al.  Lean production in healthcare: a simulation-based value stream mapping in the physical therapy and rehabilitation department of a public hospital , 2016 .

[32]  Ram Narasimhan,et al.  A Comparison of North American and European Future Purchasing Trends , 1996 .

[33]  Bruno G. Rüttimann,et al.  Lean and Industry 4.0—Twins, Partners, or Contenders? A Due Clarification Regarding the Supposed Clash of Two Production Systems , 2016 .

[34]  M. Christopher,et al.  Supply chain risk management: outlining an agenda for future research , 2003 .

[35]  Pamela J. Zelbst,et al.  Green supply chain management practices: impact on performance , 2012 .

[36]  Andrew Thomas,et al.  Profiling the resiliency and sustainability of UK manufacturing companies , 2016 .

[37]  Samir K. Srivastava,et al.  Green Supply-Chain Management: A State-of-the-Art Literature Review , 2007 .

[38]  Nekane Errasti,et al.  Three stage maturity model in SME’s toward industry 4.0 , 2016 .

[39]  C. A. van Luttervelt,et al.  Toward a resilient manufacturing system , 2011 .

[40]  Joseph Fiksel,et al.  Designing resilient, sustainable systems. , 2003, Environmental science & technology.

[41]  G. Tortorella,et al.  Implementation of Industry 4.0 and lean production in Brazilian manufacturing companies , 2018, Int. J. Prod. Res..

[42]  Martin Christopher,et al.  “Supply Chain 2.0”: managing supply chains in the era of turbulence , 2011 .

[43]  Olugbenga Mejabi,et al.  Framework for a lean manufacturing planning system , 2003, Int. J. Manuf. Technol. Manag..

[44]  C. Ajay Guru Dev,et al.  Analysis on Critical Success Factors for Agile Manufacturing Evaluation in Original Equipment Manufacturing Industry-An AHP Approach , 2016 .

[45]  Y. Sheffi.  Supply Chain Management Under The Threat Of International Terrorism , 2001 .

[46]  John Miltenburg,et al.  U-shaped production lines: A review of theory and practice , 2001 .

[47]  Virgilio Cruz-Machado,et al.  Agile and resilient approaches to supply chain management: influence on performance and competitiveness , 2012, Logist. Res..

[48]  Manisra Baramichai,et al.  Agile supply chain transformation matrix: an integrated tool for creating an agile enterprise , 2007 .

[49]  Rakesh Nagi,et al.  Multi-echelon supply chain network design in agile manufacturing , 2013 .

[50]  Rapinder Sawhney,et al.  En-Lean: a framework to align lean and green manufacturing in the metal cutting supply chain , 2007 .

[51]  M. Christopher,et al.  Building the Resilient Supply Chain , 2004 .

[52]  U. Juettner,et al.  Supply chain resilience in the global financial crisis: an empirical study , 2011 .

[53]  A. Gunasekaran,et al.  Agile manufacturing: The drivers, concepts and attributes , 1999 .

[54]  Maurizio Faccio,et al.  Assembly system design in the Industry 4.0 era: a general framework , 2017 .

[55]  Fernando Deschamps,et al.  Past, present and future of Industry 4.0 - a systematic literature review and research agenda proposal , 2017, Int. J. Prod. Res..

[56]  K. Lai,et al.  Responsive supply chain : A competitive strategy in a networked economy , 2008 .

[57]  Samuel H. Huang,et al.  Designing supply chains: Towards theory development , 2006 .

[58]  I. D. Paul,et al.  A Review on Green Manufacturing: It's Important, Methodology and its Application☆ , 2014 .

[59]  Lauri Koskela,et al.  Application of the New Production Philosophy to Construction , 1992 .

[60]  Seyed Mohammad,et al.  A Study on Total Quality Management and Lean Manufacturing: Through Lean Thinking Approach , 2011 .

[61]  Juha Hintsa,et al.  Supply Chain Security Management: an overview , 2009 .

[62]  Mudhafar Alefari,et al.  The role of leadership in implementing lean manufacturing , 2017 .

[63]  Joseph Sarkis,et al.  Green supply chain management: A review and bibliometric analysis , 2015 .

[64]  Hossein Sharifi,et al.  Agile manufacturing in practice ‐ Application of a methodology , 2001 .

[65]  Cynthia Karen Swank.  The lean service machine. , 2003, Harvard business review.

[66]  Abdulghadar Awheda,et al.  Factors related to supply chain network members in SMEs , 2016 .

[67]  Beata Mrugalska,et al.  Towards Lean Production in Industry 4.0 , 2017 .

[68]  Dimitris Mourtzis,et al.  Design and Planning of Manufacturing Networks for Mass Customisation and Personalisation: Challenges and Outlook , 2014 .

[69]  Virgilio Cruz-Machado,et al.  Supply chain performance management: lean and green paradigms , 2010, Int. J. Bus. Perform. Supply Chain Model..

[70]  Kuldip Singh Sangwan,et al.  A bibliometric analysis of green manufacturing and similar frameworks , 2015 .

[71]  Marco Leite,et al.  Agile manufacturing practices for new product development: industrial case studies , 2016 .

[72]  Virgilio Cruz-Machado,et al.  LARG index: A benchmarking tool for improving the leanness, agility, resilience and greenness of the automotive supply chain , 2016 .

[73]  Parthasarathy Garre,et al.  Applying lean in aerospace manufacturing , 2017 .

[74]  Baba Md Deros,et al.  A survey on lean manufacturing implementation in Malaysian automotive industry , 2010 .

[75]  David Dornfeld,et al.  Green Manufacturing and Sustainable Manufacturing Partnership Title Assessment of Lean and Green Strategies by Simulation of Manufacturing Systems in Discrete Production Environments , 2013 .

[76]  Ali Diabat,et al.  Analyzing the drivers of green manufacturing with fuzzy approach , 2015 .

[77]  Virginia L. M. Spiegler,et al.  Developing a resilient supply chain strategy during ‘boom’ and ‘bust’ , 2016 .

[78]  Wendy L. Tate,et al.  Green, lean, and global supply chains , 2010 .

[79]  Jeffrey M. Alden,et al.  Agile manufacturing systems in the automotive industry , 2004 .

[80]  Jochen Deuse,et al.  Leveling of low volume and high mix production based on a Group Technology approach , 2011 .

[81]  Angappa Gunasekaran,et al.  Agile manufacturing: framework and its empirical validation , 2014, The International Journal of Advanced Manufacturing Technology.

[82]  Yen-Chun Jim Wu,et al.  LEAN MANUFACTURING: A PERSPECTIVE OF LEAN SUPPLIERS , 2003 .

[83]  Ahmed M. Deif,et al.  A system model for green manufacturing , 2011 .

[84]  Peter McCullen,et al.  Achieving lean supply through agile manufacturing , 2001 .

[85]  D. Towill,et al.  Engineering supply chains to match customer requirements , 2000 .

[86]  R. A. Inman,et al.  Agile manufacturing: Relation to JIT, operational performance and firm performance , 2011 .

[87]  Claudia Colicchia,et al.  Increasing supply chain resilience in a global sourcing context , 2010 .

[88]  E. Rauch,et al.  Implementation of Lean Production in Small Sized Enterprises , 2013 .

[89]  S. Konecka,et al.  Lean and Agile Supply Chain Management Concepts in the Aspect of Risk Management , 2010 .

[90]  David J. Barnes,et al.  Supplier selection in agile supply chains: An information-processing model and an illustration , 2009 .

[91]  Angappa Gunasekaran,et al.  Agile manufacturing: A framework for research and development , 1999 .

[92]  Hans-Georg Kemper,et al.  Application-Pull and Technology-Push as Driving Forces for the Fourth Industrial Revolution , 2014 .

[93]  A. Sánchez,et al.  Lean indicators and manufacturing strategies , 2001 .

[94]  Kim Hua Tan,et al.  Green as the new Lean: how to use Lean practices as a catalyst to greening your supply chain , 2013 .

[95]  T. Kotzé,et al.  Supply chain design approaches for supply chain resilience: A qualitative study of South African fast-moving consumer goods grocery manufacturers , 2016 .

[96]  J. Worley,et al.  The role of communication and management support in a lean manufacturing implementation , 2006 .

[97]  Kasper Edwards,et al.  Application of Lean Manufacturing in Hospitals—the Need to Consider Maturity, Complexity, and the Value Concept , 2016 .

[98]  G. Seliger,et al.  Opportunities of Sustainable Manufacturing in Industry 4.0 , 2016 .

[99]  Francisco Almada-Lobo,et al.  The Industry 4.0 revolution and the future of Manufacturing Execution Systems (MES) , 2016 .

[100]  H. Carvalho,et al.  Impact of supply chain management practices on sustainability , 2014 .

[101]  John Burnett,et al.  Agile supply: rethinking systems thinking, systems practice , 2000 .

[102]  Jay Lee,et al.  A Cyber-Physical Systems architecture for Industry 4.0-based manufacturing systems , 2015 .

[103]  Erwin Rauch,et al.  Distributed manufacturing network models of smart and agile mini-factories , 2017 .

[104]  Angappa Gunasekaran,et al.  AGILE MANUFACTURING: ENABLERS AND AN IMPLEMENTATION FRAMEWORK , 1998 .

[105]  Emre Cevikcan,et al.  Lean Transformation Integrated with Industry 4.0 Implementation Methodology , 2018 .

[106]  Charlene A. Yauch,et al.  Measuring agility as a performance outcome , 2011 .

[107]  J. B. Sacomano,et al.  Industry 4.0 and Sustainability Implications: A Scenario-Based Analysis of the Impacts and Challenges , 2018, Sustainability.

[108]  R. Rashmi,et al.  Green Manufacturing: It's Tools and Techniques that can be implemented in Manufacturing Sectors , 2015 .

[109]  Virgilio Cruz-Machado,et al.  A decision-making model for Lean, Agile, Resilient and Green supply chain management , 2012 .

[110]  Abhijeet K. Digalwar,et al.  Green manufacturing performance measures: an empirical investigation from Indian manufacturing industries , 2013 .

[111]  Mashitah Mohamed Esa,et al.  Lean Manufacturing Case Study with Kanban System Implementation , 2013 .

[112]  G. Anand,et al.  Development of a framework for implementation of lean manufacturing systems , 2010 .

[113]  R. Sundar,et al.  A Review on Lean Manufacturing Implementation Techniques , 2018 .

[114]  A. R. Rahani,et al.  Production Flow Analysis through Value Stream Mapping: A Lean Manufacturing Process Case Study , 2012 .

[115]  Bodo Urban,et al.  An Ontology-Based Approach to Enable Knowledge Representation and Reasoning in Worker-Cobot Agile Manufacturing , 2017, Future Internet.

[116]  Andreja Rojko,et al.  Industry 4.0 Concept: Background and Overview , 2017, Int. J. Interact. Mob. Technol..

[117]  Eleftherios Iakovou,et al.  An analytical methodological framework for the optimal design of resilient supply chains , 2007 .

[118]  Angappa Gunasekaran,et al.  Agile manufacturing: an evolutionary review of practices , 2018, Int. J. Prod. Res..

[119]  Benita M. Beamon,et al.  Designing the green supply chain , 1999 .

[120]  Hamideh Afsarmanesh,et al.  Collaborative Networks as a Core Enabler of Industry 4.0 , 2017, PRO-VE.

[121]  Detlef Zühlke,et al.  Lean Automation enabled by Industry 4.0 Technologies , 2015 .

[122]  Sri Hartini,et al.  The Relationship between Lean and Sustainable Manufacturing on Performance: Literature Review , 2015 .

[123]  Lonnie Wilson,et al.  How to Implement Lean Manufacturing , 2009 .

[124]  Fazleena Badurdeen,et al.  Integrating lean and other strategies for mass customization manufacturing: a case study , 2012, J. Intell. Manuf..

[125]  Virgilio Cruz-Machado,et al.  Supply chain redesign for resilience using simulation , 2012, Comput. Ind. Eng..

[126]  Ping Lou,et al.  Study on multi-agent-based agile supply chain management , 2004 .

[127]  Daniel T. Jones,et al.  The machine that changed the world : based on the Massachusetts Institute of Technology 5-million dollar 5-year study on the future of the automobile , 1990 .

[128]  M. Naim,et al.  Developing Lean and Agile Supply Chains in the Uk Housebuilding Industry , 1999 .

[129]  Cathy A. Rusinko,et al.  Green Manufacturing: An Evaluation of Environmentally Sustainable Manufacturing Practices and Their Impact on Competitive Outcomes , 2007, IEEE Transactions on Engineering Management.

[130]  C. Mallika Parveen,et al.  Integration of lean and green supply chain - Impact on manufacturing firms in improving environmental efficiencies , 2011, International Conference on Green technology and environmental Conservation (GTEC-2011).

[131]  Hassan Soltan,et al.  Lean and Agile Performance Framework for Manufacturing Enterprises , 2015 .

[132]  Krisztina Demeter,et al.  Factors influencing employee perceptions in lean transformations , 2011 .

[133]  Virgílio António Cruz Machado,et al.  Generic Integration of Lean, Agile, Resilient, and Green Practices in Automotive Supply Chain , 2013 .

[134]  Norhana Arsad,et al.  A systematic review of lean implementation approaches: a proposed technology combined lean implementation framework , 2019 .

[135]  Joachim Metternich,et al.  Efficiency and Economic Evaluation of Cellular Manufacturing to Enable Lean Machining , 2013 .

[136]  Brian Fynes,et al.  Mitigation Processes – Antecedents for Building supply chain resilience , 2014 .

[137]  Christoph Herrmann,et al.  Industry 4.0 Impacts on Lean Production Systems , 2017 .

[138]  Yang Lu,et al.  Industry 4.0: A survey on technologies, applications and open research issues , 2017, J. Ind. Inf. Integr..

[139]  M. Christopher,et al.  The Supply Chain Strategy Conundrum: To be Lean Or Agile or To be Lean And Agile? , 2002 .

[140]  Alistair R. Anderson,et al.  The evolution of agile manufacturing , 2003, Bus. Process. Manag. J..

[141]  Damien Power,et al.  Use the supply relationship to develop lean and green suppliers , 2005 .

[142]  Konstantinos Salonitis,et al.  Drivers and Barriers of Lean Implementation in the Greek Manufacturing Sector , 2016 .

[143]  Michael Möhring,et al.  Industry 4.0 - Potentials for Creating Smart Products: Empirical Research Results , 2015, BIS.

[144]  Mariagrazia Dotoli,et al.  A model for supply management of agile manufacturing supply chains , 2012 .

[145]  Hossein Sharifi,et al.  A methodology for achieving agility in manufacturing organisations : An introduction , 1999 .

[146]  Yi Wang,et al.  Industry 4.0: a way from mass customization to mass personalization production , 2017 .

[147]  M. V. Assen.  Agile-based competence management: the relation between agile manufacturing and time-based competence management , 2000 .

[148]  Günther Schuh,et al.  Promoting Work-based Learning through Industry 4.0 , 2015 .

[149]  Kannan Govindan,et al.  An analysis of the drivers affecting the implementation of green supply chain management , 2011 .

[150]  Sanjiv Kumar Jain,et al.  A literature review of lean manufacturing , 2013 .

[151]  Jens P. Wulfsberg,et al.  Industry 4.0 implies lean manufacturing: Research activities in industry 4.0 function as enablers for lean manufacturing , 2016 .

[152]  Angappa Gunasekaran,et al.  Agile manufacturing practices: the role of big data and business analytics with multiple case studies , 2018, Int. J. Prod. Res..

[153]  Joseph Sarkis,et al.  The relationship between ISO 14001 and continuous source reduction programs , 2000 .

[154]  F. Chan,et al.  The link between Industry 4.0 and lean manufacturing: mapping current research and establishing a research agenda , 2018, Int. J. Prod. Res..

[155]  Wilfried Sihn,et al.  Tangible Industry 4.0: A Scenario-Based Approach to Learning for the Future of Production , 2016 .

[156]  Qiang Feng,et al.  Local implementation for green-manufacturing technology diffusion policy in China: from the user firms' perspectives , 2016 .

[157]  G. Brundtland,et al.  Our common future , 1987 .

[158]  Roberto Panizzolo,et al.  Applying the lessons learned from 27 lean manufacturers.: The relevance of relationships management , 1998 .

[159]  Remzi Seker,et al.  Big Data and virtualization for manufacturing cyber-physical systems: A survey of the current status and future outlook , 2016, Comput. Ind..

[160]  Tarun Gupta,et al.  An empirical study of just‐in‐time and total quality management principles implementation in manufacturing firms in the USA , 1997 .

[161]  A. Sanz-Lobera,et al.  Lean Service: Reassessment of Lean Manufacturing for Service Activities☆ , 2015 .

[162]  Paul R. McCright,et al.  Lean Manufacturers' Transcendence to Green Manufacturing , 2009 .

[163]  Torbjørn H. Netland,et al.  Lean product development and lean manufacturing: Testing moderation effects , 2018, International Journal of Production Economics.

[164]  Susana Garrido Azevedo,et al.  Modelling green and lean supply chains: An eco-efficiency perspective , 2017 .

[165]  Siti Norezam Othman,et al.  Impact of lean practices on operations performance and business performance , 2013 .

[166]  Virgilio Cruz-Machado,et al.  Integrating Lean, Agile, Resilience and Green Paradigms in Supply Chain Management (LARG_SCM) , 2011 .

[167]  Sanjay Bhasin,et al.  Lean viewed as a philosophy , 2006 .

[168]  Susana Garrido Azevedo,et al.  Trade-offs among Lean, Agile, Resilient and Green Paradigms in Supply Chain Management: A Case Study Approach , 2014 .

[169]  Saiful Bahri Mohamed,et al.  Sustainable manufacturing practices in Malaysian palm oil mills: Priority and current performance , 2017 .