Title: Basic formation in streamlining lean practices in manufacturing operations - a review

Authors: Muhamad Zaki Yusup; Wan Hasrulnizzam Wan Mahmood; Mohd Rizal Salleh

Addresses: Sustainable and Responsive Manufacturing Research Group, Faculty of Engineering Technology, Technology Campus, Universiti Teknikal Malaysia Melaka, 75450 Hang Tuah Jaya, Melaka, Malaysia; Department of Quality and Productivity, Kolej Kemahiran Tinggi MARA Kuantan, Km 8, Jalan Gambang, 25150 Kuantan, Pahang, Malaysia ' Sustainable and Responsive Manufacturing Research Group, Faculty of Engineering Technology, Technology Campus, Universiti Teknikal Malaysia Melaka, 75450 Hang Tuah Jaya, Melaka, Malaysia ' Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, 76100 Hang Tuah Jaya, Melaka, Malaysia

Abstract: Lean production, also known as lean manufacturing was a popular social-technical management philosophy, and widely accepted as an effective approach in improving the operational performance management since it was first introduced in the early 90s. However, most of lean practice is often adopted based on own understanding with reference to the success achieved by others. This potentially creates the gap and eventually affects its implementation performance. Therefore, the aims of this article is to propose based on literature, the basic concept of lean practices that can be considered by manufacturers as a starting point or to strengthen the performance of its regardless of firm size (small, medium or large manufacturing industry). By referring to the nine categories of manufacturing waste (inventory, waiting time, transportation, inefficient energy utilisation, over-processing, over-production, unnecessary motion, and defects), lean practices can be streamlined through the four formation stages, i.e., planning and product development, production planning and scheduling, manufacturing processes, and functional and visual inspection. This can be realised by focusing on three dimensions of implementation, namely input, product revolutionary processes, and output. The proposed concept is useful as a basic guideline, primarily for manufacturers to plan and develop a better strategy for a better performance results.

Keywords: lean production; lean manufacturing; lean performance; conceptual modelling; manufacturing operations; literature review; manufacturing industry; lean practices; manufacturing waste; product development; production planning; scheduling; manufacturing processes; inspection.

DOI: 10.1504/IJAOM.2015.075024

International Journal of Advanced Operations Management, 2015 Vol.7 No.4, pp.255 - 273

Received: 23 Feb 2015
Accepted: 28 Aug 2015
Published online: 29 Feb 2016 *

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