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Continuous process flow is a prerequisite of lean systems as it helps to reduce throughput times, improve quality, minimize operational costs, and shorten delivery times. The purpose of this paper is to empirically demonstrate the application of a methodology that combines a time‐based study, discrete‐event simulation and the trial and error method to enable a leaner process through more efficient line balancing and more effective flow for a park homes production process. This method is replicable across other contexts and industry settings.

The paper reviews the UK park homes production industry and, specifically, a major factory that builds these homes. It compares the factory method to traditional on‐site construction methods. An empirical study of production times was carried out to collect data in order to analyse the current workload distribution and the process flow performance of the park homes production process. Finally, seven discrete‐event simulation models were developed in order to test different scenarios and define the optimum line balance for every section of the production process.

By combining time study, discrete‐event simulation and trial and error methods, the workload distribution and process flow performance of the park homes production line were analysed and improved. A reduction of between 1.82 and 36.32 percent in balancing losses in some sections of the process was achieved.

This paper supports current knowledge on process flow improvement and line balancing by exploring and analysing these issues in a real‐life context. It can be used to guide production management practitioners in their selection of methods and demonstrates how they are exploited when seeking to improve process flow, efficiency and line balancing of production operations.

The study uses a real industrial application to demonstrate how the methodological combination and deployment of process flow improvement strategies, such as time study, simulation, and trial and error, can help organisations achieve process flow improvements and, as a consequence, a leaner production process.

The purpose of this paper is to better define the relationships between product variety and lean production in enabling mass customization in industrialized homebuilding.

This study includes a case study analysis of two housing plants that instituted lean production systems. For each company, the case study documented the company's background, the product choice offered, the lean implementation approach used, the results obtained, and the effect of product choice on the lean implementation. Using these case study findings, common trends were identified and used to develop guidelines for an effective mass customization strategy for industrialized homebuilders. This paper summarizes the extensive findings for one of the two plants and provides the recommended guidelines developed from common trends identified at both plants.

Case study findings indicated that product choice does not necessarily make the implementation of lean concepts more difficult. In fact, good lean concepts (e.g. continuous flow, pull system, workload leveling, defect‐free processes, standard tasks, good visual control, and reliable technology) were also good concepts for (or easily accommodated) handling a range of product choice.

Research findings are limited by the small number of plants involved in the study.

The paper makes an important contribution to the understanding of both lean production and mass customization, identifying the lean principles that facilitate mass customization for industrialized homebuilders. Findings also provide useful guidelines for builders interested in better addressing specific customer needs, while managing the operational complexities resulting from product variety.

The purpose of this paper is to present a road map to implement Lean-Kaizen concept using value stream mapping (VSM) to identify hidden continuous improvement opportunities in a small and medium-sized enterprise (SME) located at the non-capital region of India.

From the collected data, a current state map was prepared that indicated the current operating situation of selected SME. The takt time was calculated and those processes which attained higher cycle time (C/T) than takt time were identified. The continuous flow processing was achieved by adjusting C/T of each process and supermarket pull system was developed to control the production at the workstations. Finally, a future state map was developed that served as a guide for future lean activities. Few problems were identified to realize the future state. The “5-why” analysis was used for identifying root causes of these problems and Kaizen events were proposed as solutions. In this case study, one Kaizen event was identified in which brainstorming technique was used to control the variation caused by unorthodox fixture design for clamping and de-clamping of case product and thus eliminated non-value-added activities performed by the operator on a milling machine.

Before and after implementation of value stream map, the data obtained were analyzed and eliminated rework time, reduced inventory level, reduced lead time and C/T, improved productivity and product quality are presented as finding. Lean-Kaizen provides a better chance for every individual of the industry to have a hand in achieving organization’s goals to attain continuous progress in productivity and quality of the product. Even good understanding of the concept of lean tools and techniques by SMEs, the employee willingness and motivation to identify and eliminate wastes are found feeble.

This study is among best practices to identify hidden improvement opportunities in the regular production of the product to increase productivity and improve quality using value stream map. The research paper gives useful understandings to the lean implementers, Kaizen identifiers, consultants and researchers.

The purpose of the paper is to explore the application of radio frequency identification (RFID) to improve traceability in a flow of granular products and to illustrate examples of special issues that need to be considered when using the RFID technique in a process industry setting.

The paper outlines a case study at a Swedish mining company, including experiments to test the suitability of RFID to trace iron ore pellets (a granular product) in parts of the distribution chain.

The results show that the RFID technique can be used to improve traceability in granular product flows. A number of special issues concerning the use of RFID in process industries are also highlighted, for example, the problems to control the orientation of the transponder in the read area and the risk of product contamination in the supply chain.

Even though only a single case has been studied, the results are of a general interest for industries that have granular product flows. However, future research in other industries should be performed to validate the results.

The application of RFID described in this paper makes it possible to increase productivity and product quality by improving traceability in product flows where traceability normally is problematic.

Prior research has mainly focused on RFID applications in discontinuous processes. By contrast, this paper presents a novel application of the RFID technique in a continuous process together with specific issues connected to the use of RFID.

The purpose of this paper is to explore the applicability of lean construction (LC) concepts and tools in necessary, but non-value-added activities (NVAA) in small and medium-sized enterprises (SME). The application of the lean tools in this way facilitates the flow of information and handling material, improving productivity, quality and performance. Finally, practical results motivate a discussion on the real potential of LC principles and on the challenges related to its implementation.

The methodology makes use of direct involvement in the environment under study. Some of the activities performed were the value stream mapping and time and motion studies of the company’s process selected, identification of wastes and the proposition of improvements to be implemented.

The main findings are related to the benefits of the application of LC not only in value-added activities but in activities that can influence the development and workforce planning, especially for SME businesses. This company should be able to achieve better management decisions and results after implementing the LC principles, overcoming the limited resources.

This proposed method helps in overcoming the lack of systematic procedures, enabling LC in activities that not add value properly. It has the advantage of integrating existing tools and models effectively, which not only improve the shortcomings of the conventional methods but also result in more convenient calculation and application.

We undertake an empirical study of the well‐known product‐process matrix using data collected from 128 plants. Our analysis indicates that the relationship between product structure and process structure is significant, but not strong. Furthermore, less than half of the plants operate near the diagonal of the matrix. We found that the off‐diagonal plants are using innovative initiatives to overcome the lack of product structure and process structure match. As a result, we propose that a third dimension be added to the product‐process matrix that measures how aggressively plants are implementing these innovative initiatives, thereby explaining their off‐diagonal behavior.

The purpose of this paper is to gain insights about the applicability of Lean principles in software industry along with the Lean implementation issues.

Exploratory case studies have been carried out in five software companies. Data were collected by observation and semi-structured interviews with project managers. In this paper, case organizations are categorized as product vs project software development (SD) organization.

It is found that although Lean principles are being adopted in SD projects, application of all Lean principles is not visible. This research reveals that value and flow are more relevant in SD organizations, while value stream, pull and perfection are not conspicuous.

This paper would prove invaluable to lean practitioners and researchers to gain knowledge in lean SD. The paper puts forward the key issues that should be addressed for successful adoption of lean in SD. This study set out to determine the practitioners’ perception of the applicability of lean principles in SD projects. It provides a sound basis for further empirical research on adoption of lean principles in SD organizations.

The traditional product-costing continuum is too limited to account for the new mass customization approach currently used by many corporations in many industries. Mass customization has changed the nature of many transactions, activities and, indeed, the very essence of many manufacturing companies, who have become more of assemblers than manufacturers. These new developments necessitate establishing new way of accounting for proper planning and control. After tracing the development of the mass customization approach from modular manufacturing into common platforms applied in one firm, and then shared by a group of firms, the paper explains the benefits of these approaches to both manufacturers and their suppliers. The central theme of this paper is to develop a product costing system for mass customization. It begins with the traditional product-process matrix in operations management literature and adds to it two elements: firm size and the modular manufacturing method. The rationale for this addition is that modular manufacturing is the best mass customization method; firm size and mass customization are inherently related as indicated by the typical evolutionary pattern of production processes. At this point, the operations management taxonomy is renamed the modular-process matrix; this matrix displays three groups of major activities: manufacturing, supplemental manufacturing, and assembling activities. These three activity groups provide the basis for developing a new set of accounts and a ledger system to account for specific customer orders developed by mass-customization processes.

This study aims to seek to advance a system dynamics-discrete event hybrid simulation modelling concept useful for taking improvement decisions where one needs to consider the interactions between human factors and process flow elements in lean manufacturing systems.

A unique approach is taken to hybrid simulation modelling where the whole problem situation is first conceptualized using a causal loop diagram and stock and flow diagram, before transmitting to a hybrid simulation model. The concept is intended to simplify the simulation modelling process and make the concept pliable for use in various types of lean manufacturing problem situations.

The hybrid simulation modelling concept was applied to a lean manufacturing case where quality performance was sporadic mainly because of production pressures. The hybrid modelling concept revealed a solution that advanced full compliance with lean and one that required changes in job scheduling policies to promote both continuous improvement and throughput increases.

Because non-tangible aspects of lean were objectively assessed using the hybrid modelling concept, the study is an advancement towards establishing a credible link between human resource aspects of lean and the performance of an organization.

The applied hybrid model enabled managers in the plant navigate the trade-off decision they often face when choosing to advance production output ahead of continuous improvement practices.

System dynamics-discrete event hybrid simulation modelling is a rarity in lean manufacturing systems.

This paper reports on an investigation of the integration of symbolic computation and reasoning into highly computerized numerically‐based realtime control systems for complex plant process management. This is the natural next step in an evolving maturation of the use of computers for automated monitoring and control of continuous processes. A particular implementation involving nuclear power plant intelligent monitoring is being developed from which overall principles and specifications can be distilled, ultimately leading to a general methodology that can be applied to other continuous plant processes.