Development of a framework for implementation of lean manufacturing systems

Researchers worldwide have proposed various frameworks for Lean Manufacturing (LM). A review of these frameworks reveals that many frameworks fall under the category of 'design/conceptual framework' that provides information about 'what constitutes LM' and few under the category of 'implementation framework', which describes 'how to implement LM'. A further comparative analysis of these implementation frameworks reveals that they suffer from shortcomings. In this paper, an attempt has been made to propose a new framework for LM implementation to resolve these shortcomings. The main feature of the proposed framework is that the LM implementation is divided into several levels/stages. At each level, the associated tools/techniques/practices/procedures (referred as elements in short) of LM to be utilised are introduced. The proposed framework is only a conceptual model and needs empirical validation.

[1]  Amrik S. Sohal,et al.  Developing a lean production organization: an Australian case study , 1996 .

[2]  Mohamed Mohamed Naim,et al.  Applying lean thinking: a case study of an Indian steel plant , 2004 .

[3]  Varun Grover,et al.  Special Section: Toward a Theory of Business Process Change Management , 1995, J. Manag. Inf. Syst..

[4]  G. Anand,et al.  Development of a framework for lean manufacturing systems , 2009 .

[5]  B. G. Dale,et al.  Lean production: A study of application in a traditional manufacturing environment , 2000 .

[6]  Angappa Gunasekaran,et al.  Implementation of just-in-time in a small company: A case study , 1997 .

[7]  C. K. Prahalad,et al.  Fortune at the bottom of the pyramid, the: eradicating poverty through profits , 2006 .

[8]  Jeffrey K. Liker,et al.  The Toyota Product Development System: Integrating People, Process And Technology , 2006 .

[9]  Pascal Dennis,et al.  Lean Production Simplified : A Plain-Language Guide to the World's Most Powerful Production System , 2002 .

[10]  Jaideep Motwani,et al.  Successful implementation of TPS in a manufacturing setting: a case study , 1997 .

[11]  David Brunt,et al.  From Current State to Future State: Mapping the Steel to Component Supply Chain , 2000 .

[12]  Surendra M. Gupta,et al.  Implementation of just-in-time methodology in a small company , 1995 .

[13]  R. Smeds Managing Change towards Lean Enterprises , 1994 .

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

[15]  S. K. Mukhopadhyay *,et al.  Kanban implementation at a tyre manufacturing plant: a case study , 2005 .

[16]  Kenneth R. Morrison,et al.  Lean manufacturing optimization of automotive motor compartment system , 1996 .

[17]  Terry Wallace,et al.  Innovation and hybridization: Managing the introduction of lean production into Volvo do Brazil , 2004 .

[18]  D. Earl Kline,et al.  Benchmarking performance measurement and lean manufacturing in the rough mill , 2006 .

[19]  Amber Nicole Dudley,et al.  The application of lean manufacturing principles in a high mix low volume environment , 2005 .

[20]  Ravi Shankar,et al.  Lean philosophy: implementation in a forging company , 2008 .

[21]  Uday M. Apte,et al.  Applying lean manufacturing principles to information intensive services , 2004, Int. J. Serv. Technol. Manag..

[22]  A. Gunasekaran,et al.  Improving operations performance in a small company: a case study , 2000 .

[23]  Richard A. Wysk,et al.  Improving Production with Lean Thinking , 2006 .

[24]  James P. Womack,et al.  Lean Thinking: Banish Waste and Create Wealth in Your Corporation , 1996 .

[25]  H.-J. Jo,et al.  The mutation of the Toyota Production System: adapting the TPS at Hyundai Motor Company , 2007 .

[26]  Jon C. Yingling,et al.  Quantifying benefits of conversion to lean manufacturing with discrete event simulation: A case study , 2000 .

[27]  Nick Rich,et al.  Value stream mapping , 1999 .

[28]  Dennis F. X. Mathaisel,et al.  An exploratory analysis in applying lean manufacturing to a labor‐intensive industry in China , 2005 .

[29]  M. L. Emiliani,et al.  Using value‐stream maps to improve leadership , 2004 .

[30]  Serge Lambert,et al.  Adaptation of JIT phylosophy and Kanban technique to a small-sized manufacturing firm; a project management approach , 1998 .

[31]  M. Yasin,et al.  A conceptual framework for effective implementation of JIT , 1998 .

[32]  Christer Karlsson,et al.  A lean and global smaller firm , 1997 .

[33]  Jochen Czabke Lean thinking in the secondary woodproducts industry : challenges and benefits , 2007 .

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

[35]  A. F. Rentes,et al.  Utilising Simulation to Enhance Value Stream Mapping: A Manufacturing Case Application , 2002 .

[36]  Manoj Kumar Tiwari,et al.  Implementing the Lean Sigma framework in an Indian SME: a case study , 2006 .

[37]  Jaideep Motwani,et al.  Quality issues in lean production implementation: A case study of a French automotive supplier , 1999 .

[38]  N. A. Scott Lean conversion and Genba Shikumi , 2007 .

[39]  Elaine Aspinwall,et al.  Total quality management implementation frameworks: Comparison and review , 2000 .

[40]  Jaideep Motwani,et al.  A business process change framework for examining lean manufacturing: a case study , 2003, Ind. Manag. Data Syst..

[41]  Jay Jina,et al.  Applying lean principles for high product variety and low volumes: some issues and propositions , 1997 .

[42]  A. Sohal,et al.  Lean Production: Experience among Australian Organizations , 1994 .

[43]  Christopher S Kim,et al.  Lean health care: what can hospitals learn from a world-class automaker? , 2006, Journal of hospital medicine.

[44]  Bernard J. Schroer,et al.  Simulation as a tool for continuous process improvement , 1999, WSC '99.

[45]  Chandandeep Grewal,et al.  An initiative to implement lean manufacturing using value stream mapping in a small company , 2008, Int. J. Manuf. Technol. Manag..

[46]  P. Hines,et al.  Learning to evolve: A review of contemporary lean thinking , 2004 .

[47]  Julian M. Allwood,et al.  Lean manufacturing in temperature dependent processes with interruptions , 2003 .

[48]  Michael Lewis,et al.  Lean production and sustainable competitive advantage , 2000 .

[49]  H. Van Landeghem,et al.  Analysing the effects of Lean manufacturing using a value stream mapping-based simulation generator , 2007 .

[50]  Rosario Domingo,et al.  Materials flow improvement in a lean assembly line: a case study , 2007 .

[51]  Hiroshi Katayama,et al.  Lean production in a changing competitive world: a Japanese perspective , 1996 .

[52]  Fredrik Ohlsson,et al.  Lean manufacturing at Volvo Truck Production Australia : development of an implementation strategy , 2005 .

[53]  Nick Oliver,et al.  Lean production and manufacturing performance improvement in Japan, the US and UK 1994-2001 , 2002 .

[54]  Kelly Ann Goforth Adapting Lean Manufacturing Principles to the Textile Industry , 2008 .

[55]  Frank Liou AC 2007-273: CAN LEAN MANUFACTURING BE APPLIED TO UNIVERSITY LABORATORIES? , 2007 .

[56]  D. Mottershead Introducing lean manufacturing at ESI , 2001, PICMET '01. Portland International Conference on Management of Engineering and Technology. Proceedings Vol.1: Book of Summaries (IEEE Cat. No.01CH37199).

[57]  Vaibhav Gupta,et al.  Application of value stream mapping for lean operations and cycle time reduction: an Indian case study , 2005 .

[58]  Chris Hakes Total quality management : the key to business improvement : a Pera International executive briefing , 1991 .

[59]  Jan Holmström,et al.  Is just‐in‐time applicable in paper industry logistics? , 1998 .

[60]  Christer Karlsson,et al.  Sequences of manufacturing improvement initiatives: the case of delayering , 2000 .

[61]  S. M. James‐Moore,et al.  Is lean manufacture universally relevant? An investigative methodology , 1997 .

[62]  Christer Karlsson,et al.  Change processes towards lean production , 1995 .

[63]  Om Prakash Yadav,et al.  Implementation of Lean Manufacturing Principles in Auto Industry , 2006 .

[64]  A. Graves,et al.  Implementing Lean in aerospace-challenging the assumptions and understanding the challenges , 2003 .

[65]  G. Anand,et al.  Simulation model for the design of lean manufacturing systems - a case study , 2009 .

[66]  Kenneth R. Morrison,et al.  Transformation to lean manufacturing by an automotive component supplier , 1996 .

[67]  Pär Åhlström,et al.  Assessing changes towards lean production , 1996 .

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

[69]  G. Anand,et al.  DEVELOPMENT OF A FRAMEWORK FOR WORLD-CLASS MAINTENANCE SYSTEMS , 2006 .

[70]  Richard Lee Storch,et al.  Improving flow to achieve lean manufacturing in shipbuilding , 1999 .