International Journal of Lean Enterprise Research (7 papers in press)
Using Lean Six Sigma Methodologies to Improve Operational Performance in Foundries
by Faisal Aqlan
Abstract: Metal casting, one of the oldest manufacturing processes, is the introduction of a molten metal into a mold where after solidification, the metal takes on the shape of the molded cavity. The metal casting industry is a competitive, always evolving industry. While practices typically remain the same, the market fluctuates year to year. This forces companies and foundries to consistently adapt to an ever changing demand and improve their processes. To do so, foundries need to eliminate wastes in their process and ensure they produce highest quality castings. In this paper, we discuss an initiative for Lean Six Sigma process improvement in casting industry. A framework for selecting the proper problem solving methodology is presented. Several process improvement projects were identified and five projects were selected. Lean and Six Sigma problem solving methods were used.
Keywords: Lean manufacturing; Six Sigma; process improvement; problem solving; casting industry.
Work Culture Enablers: Hierarchical Design for Effectiveness & Efficiency
by Rajender Kumar, Vikas Kumar, Sultan Singh
Abstract: The manufacturing process also referred as the transformation process (converting raw material into finished products) consumes the huge amount of resources , which severely affects sustainability. Extensive initiatives are sought to stand to the Make in India proposal of the Indian Prime Minister, which are primarily people dependent. The present work seeks to investigate the enablers of peoples work culture to implement PMs commandments along with their interdependence and hierarchy levels in Indian manufacturing sector for which the Interpretive Structural Modelling (ISM) has been used. While understanding the contextual relationships among the identified enablers MICMAC analysis is used to categorize the identified enablers according to their importance in the organization. The investigations reported that a twin enabler Compettitude (Competence + Attitude)  is the driving enabler for a zero waste culture paradigm to sustainable progression of the PMs initiative. Consistency is next reported as the dependent enabler for a healthy work culture on all other enablers.
Keywords: Work Culture; Consistency; Compettitude; manufacturing organization; performance.
Lean Manufacturing Awareness and Its Implementation Status in the Apparel Industry in Bangladesh
by Abul Bashar, Ahsan Hasin
Abstract: Most recently the apparel manufacturing industries of Bangladesh have been greatly affected by several factors such as global competition, increased manufacturing and transportation cost, changing buyer habits and expected social compliance. However the literature study reveals that the use of advanced manufacturing and management system such as lean manufacturing system allows manufacturing firms to be more successful even operating in a more challenging and competitive environment. To analyze the lean manufacturing awareness and its current status of implementation in the apparel industry in Bangladesh, a survey was conducted. This paper addresses the awareness level of lean manufacturing system, lean tools and techniques and the degree of lean implementation in the apparel industry.
Keywords: Apparel industry; Lean manufacturing; Lean awareness; Lean tools and techniques; Implementation.
A comparative analysis of lean implementations in NHS England hospitals.
by Adnan Deara, Mohamed Deara, Christopher Bamber, Enis Elezi
Abstract: The paper investigates and documents the effect of implementing lean in NHS England Hospitals through an evaluation of one quantitative study that questioned a large number of NHS staff and three case study reviews of implantation of lean projects. The purpose of lean implementation in these UK studies has been shown as predominantly to improve times, use staff more effectively, improve quality, decrease waste and reduce cost and smooth arrivals of patient demands. Moreover, lean in the NHS is used to utilise the available resources in the best manner. This paper indicates that most of the barriers which have been identified by 88% of the interviewed people, from the NHS quantitative study, were due to the terminology of new language and consequently poor communications of lean principles. The critical success factors elicited from this study include a widespread commitment of project success and the application effective governance. Setting clear goals, project planning and competent project teams, are considered by respondents and seen in the analysis of the three case studies reviewed in this study; all play an important role in successful NHS lean projects.
Keywords: Lean practices; UK Hospitals; Quality Improvement; Effective Organisations; Enhanced Operations; Leadership and Governance.
Performance measurement for lean manufacturing strategies in manufacturing industry
by Virender Chahal, M.S. Narwal
Abstract: In the present scenario, Lean System (LS) is used as a primary system in modern developing industries to provide better quality and high good customer satisfaction. LS provide optimize results in available resources. LS is a combination of different lean strategies but it is too difficult to select most appropriate lean manufacturing strategies (LMS) for the industry. This paper focuses to measure the performance of implemented LMS to select appropriate for the industry. A case study is performed in the industry to calculate the performance of LMS. Also a mathematical model will generate to calculate the LMS performance. This research paper provides an optimized and systematic mathematical model to select appropriate LMS according to their performance within available resources. This paper is based on practical measurement and provides a performance measurement model for LMS to evaluate their performance in the implemented industry.
Keywords: lean system; lean manufacturing strategies; LMS; LMS performance; performance measurement model.
A Lean Framework For Reusing Knowledge Introducing Engineering Checksheets
by Dag Bergsjö, Amer Catic, Daniel Stenholm
Abstract: In this study, we have brought several knowledge management theories and
practices together and have investigated the valuable aspects in each one of them.
Throughout our research, we have enabled knowledge reuse to be a guiding principle and
have attempted to formulate an improved method for documenting knowledge. The focus
has been to create actionable and reusable knowledge presented at the right time, to the
right audience in a digitally condensed format that may hopefully will lead to improved
decision-making, thereby potentially driving innovation and effectively reducing overall
product realization lead-time. We have explored the effect of the Engineering Checksheet
concept in two separate case studies where it was implemented in a real-life setting. The
concept showed positive results as a knowledge carrier both for reuse by experienced and
Keywords: Organizational learning; knowledge management practice; knowledge sharing; explicit knowledge; decision support; case studies; engineering checksheet.
Content Validation of an Assessment Tool to Measure Lean Deployment Based on the Toyota Production System and Toyota Way
by Nicholas Loyd
Abstract: This research focused on the development and achievement of content validity of an assessment tool to measure an organizations level of Lean deployment based on the Toyota Production System-Toyota Way model. Survey items were developed from a first-person perspective in order to capture an assessment of an organizations culture from the inside out. The survey was subjected to subject matter expert review for qualitative content validation. Quantitative methods such as parametric and non-parametric exploratory factor analysis and reliability analysis were used to evaluate and modify the structure of the assessment tool. The result of this research was an assessment tool that exhibits strong content validity and consists of 30 items that measure the 5 constructs of the Toyota Production System and the Toyota Way culture.
Keywords: lean production systems; Toyota Production System; lean manufacturing; culture; content validation; lean strategy; factor analysis; employee involvement\r\n.