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The imperative to conserve resources and minimize operational expenses has spurred a notable increase in the adoption of lean manufacturing within the context of the circular economy across diverse industries in recent years. However, a notable gap exists in the research landscape, particularly concerning the implementation of lean practices within the pharmaceutical industry to enhance circular economy performance. Addressing this void, this study endeavors to identify and prioritize the pivotal drivers influencing lean manufacturing within the pharmaceutical sector.

The outcome of this rigorous examination highlights that “Continuous Monitoring Process for Sustainable Lean Implementation,” “Management Involvement for Sustainable Implementation” and “Training and Education” emerge as the most consequential drivers. These factors are deemed crucial for augmenting circular economy performance, underscoring the significance of management engagement, training initiatives and a continuous monitoring process in fostering a closed-loop practice within the pharmaceutical industry.

The findings contribute valuable insights for decision-makers aiming to adopt lean practices within a circular economy framework. Specifically, by streamlining the process of developing a robust action plan tailored to the unique needs of the pharmaceutical sector, our study provides actionable guidance for enhancing overall sustainability in the manufacturing processes.

This study represents one of the initial efforts to systematically identify and assess the drivers to LM implementation within the pharmaceutical industry, contributing to the emerging body of knowledge in this area.

The purpose of this paper is twofold: first, a case study on applying lean principles in manufacturing operations to redesign and optimize an electronic device assembly process and its impact on performance and second, introducing cardboard prototyping as a Kaizen tool offering a novel approach to testing and simulating improvement scenarios.

The study employs value stream mapping, root cause analysis, and brainstorming tools to identify root causes of poor performance, followed by deploying a Kaizen event to redesign and optimize an electronic device assembly process. Using physical models, bottlenecks and opportunities for improvement were identified by the Kaizen approach at the workstations and assembly lines, enabling the testing of various scenarios and ideas. Changes in lead times, throughput, work in process inventory and assembly performance were analyzed and documented.

Pre- and post-improvement measures are provided to demonstrate the impact of the Kaizen event on the performance of the assembly cell. The study reveals that implementing lean tools and techniques reduced costs and increased throughput by reducing assembly cycle times, manufacturing lead time, space utilization, labor overtime and work-in-process inventory requirements.

This paper adds a new dimension to applying the Kaizen methodology in manufacturing processes by introducing cardboard prototyping, which offers a novel way of testing and simulating different scenarios for improvement. The paper describes the process implementation in detail, including the techniques and data utilized to improve the process.

Lean management tools are becoming increasingly applied in different types of organizations around the world. These tools have shown their significant contribution to improving business performance. In this vein, the purpose of this paper is to examine the influence of lean management on both occupational safety and operational excellence in Tunisian companies.

A survey was conducted among Tunisian companies, and it resulted in the collection of 62 responses that were analyzed using the software SPSS. In addition, a conceptual model linking the practices of the three basic concepts was designed to highlight the hypotheses of the research. Subsequently, factor analysis and structural equation method analysis were conducted to assess the validation of the assumptions.

The results obtained have shown that lean management has a significant impact on occupational safety. Similarly, occupational safety has a significant impact on operational excellence. However, lean management does not have a significant impact on operational excellence.

This work highlighted the involvement of small and medium-sized enterprise’s managers from emerging economies in the studied concepts’ practices. Likewise, it testified to the impacts of lean management on occupational safety and operational excellence in the Tunisian context.

Lean construction (LC) is an innovative approach in the construction industry that has shown significant success in developed countries. Although LC has potential in the construction sector of Pakistan, it has not been extensively explored. This study aims to address this knowledge gap by identifying and predicting current lean practices and assessing the strengths and weaknesses of LC implementation in Pakistan.

Using robust statistical methods to analyze 92 valid responses, the study reveals that approximately 54% of lean practices are currently in use in the construction industry of Pakistan, with a population mean ranging from 52.7% to 55.6%.

Surprisingly, the research identifies instances where some construction firms in Pakistan are implementing LC practices, even though they have only a limited understanding of its underlying principles. Notably, certain subprinciples, such as visual management, top management commitment to change, employee training, process cycle time reduction and production optimization, are less integrated within the construction industry. Exploring the possibility of implementing LC, recommendations for strategies to implement LC in Pakistan are suggested, aligning with the conceptual model proposed by the researchers.

The novelty of this work offers insights that can serve as a comprehensive guide for developing nations. It provides a structured approach to assess and benchmark LC practices, which, in turn, can contribute to a more efficient and effective construction industry. Moreover, the strategies proposed in this research can aid developing countries in the efficient implementation of LC. This will have a positive implication for both economic and developmental outcomes.

This paper presents a new and well-structured framework that aims to assess the current environmental impact from a Greenhouse Gas (GHG) emissions perspective. This tool includes a new set of Lean Key Performance Indicators (KPIs), which translates the well-known logic of Overall Equipment Effectiveness in the field of GHG emissions, that can progressively detect industrial losses that cause GHG emissions and support decision-making for implementing improvements.

The new metrics are presented with reference to two different perspectives: (1) to highlight the deviation of the current value of emissions from the target; (2) to adopt a diagnostic orientation not only to provide an assessment of current performance but also to search for the main causes of inefficiencies and to direct improvement implementations.

The proposed framework was applied to a major company operating in the plywood production sector. It identified emission-related losses at each stage of the production process, providing an overall performance evaluation of 53.1%. The industrial application shows how the indicators work in practice, and the framework as a whole, to assess GHG emissions related to industrial losses and to proper address improvement actions.

This paper scrutinizes a new set of Lean KPIs to assess the industrial losses causing GHG emissions and identifies some significant drawbacks. Then it proposes a new structure of losses and KPIs that not only quantify efficiency but also allow to identify viable countermeasures.

The purpose of this study is to propose a new mapping tool called Circular Value Stream Mapping (C-VSM) that combines Circular Economy principles with Lean tools to enhance sustainability performance in operations.

To develop the C-VSM tool, the researchers conducted a literature review and a focus group. The tool was then applied to two real case studies in the agri-food sector, specifically analyzing an artichoke and olive oil producer, to assess its validity and effectiveness.

The study introduces the Circular Resource Box (CRB) as a key innovation in the C-VSM tool. This visual representation effectively captures resource circularity and how resources and wastes are managed, making it easy to identify circularity in the production process. By combining qualitative and quantitative information with this visual representation, companies can identify improvement opportunities aligned with the CE.

The research is limited in scope as it focuses on the application of the C-VSM tool in the agri-food sector. Further research could explore its applicability in other industries and settings to understand its broader impact.

The C-VSM tool provides practical benefits to companies seeking to transition from linear to circular production processes. It enables practitioners to identify opportunities to reduce environmental impacts and optimize production operations in line with CE.

The introduction of the C-VSM tool is a novel approach that bridges the gap between Lean Manufacturing and CE concepts, advancing the understanding of how CE thinking can be effectively implemented in operations.

This paper proposes a new metric, named Operational Space Efficiency (OpSE), intended to diagnose and quantify the inefficient use of floor space for stocking materials in industrial workstations. OpSE presents a formulation analogous to the well-known Overall Equipment Effectiveness and can be obtained as the product of three distinct indicators: Standard Compliance Effectiveness, Standards Selection Effectiveness and Design Space-usage Effectiveness.

This indicator scrutinizes how usefully floor space in workstations is used to temporarily stock materials in the form of raw materials, semi-finished products, parts and components. It is suited for analyzing fixed-position layouts as well as product layouts typical of repetitive manufacturing settings, such as assembly lines in the automotive sector. The proposed indicator leverages an appropriate loss structure that features those factors affecting floor space utilization in workstations with regard to supplying and stocking materials.

An Italian manufacturer in the field of electro-technology was used as an industrial case study for the application of the methodology. The application shows how the three indicators work in practice, the effectiveness of OpSE and the methodology as a whole, in diagnosing floor space usage inefficiencies and in properly addressing improvement actions of the internal logistics in industrial settings.

The paper scrutinizes some important Key Performance Indicators (KPIs) dealing with space usage efficiency and identifies some significant drawbacks. Then it suggests a new, inclusive structure of losses and a KPI that not only measures efficiency but also allows to identify viable countermeasures.

This paper recommends a method entitled “SMED 4.0” as a development of conventional single minute exchange of die (SMED) to avoid defect occurrence during production and improve sustainability, besides reducing setup time.

The method builds upon an extensive literature review and in-depth explorative research in SMED and zero defect manufacturing (ZDM). SMED 4.0 incorporates an evolutionary stage that employs predict-prevent strategies using Industry 4.0 technologies including the Internet of Things (IoT) and machine learning (ML) algorithms.

It presents the applicability of the proposed approach in (1) identifying the triple bottom line (TBL) criteria, which are affected by defects; (2) predicting the time of defect occurrence if any; (3) preventing defective products by performing online setting on machines during production as needed; (4) maintaining the desired quality of the product during the production and (5) improving TBL sustainability in manufacturing processes.

The extended view of SMED 4.0 in this research, as well as its analytical approach, helps practitioners develop their SMED approaches in a more holistic way. The practical application of SMED 4.0 is illustrated by implementing it in a real-life manufacturing case.

The aim of this paper is to explore the possibility of using the Define-Measure-Analyze-Improve-Control (DMAIC) cycle, process mining (PM) and multi-criteria decision methods in an integrated way so that these three elements combined result in a methodology called the Agile DMAIC cycle, which brings more agility and reliability in the execution of the Six Sigma process.

The approach taken by the authors in this study was to analyze the studies arising from this union of concepts and to focus on using PM tools where appropriate to accelerate the DMAIC cycle by improving the first two steps, and to test using the AHP as a decision-making process, to bring more excellent reliability in the definition of indicators.

It was indicated that there was a gain with acquiring indicators and process maps generated by PM. And through the AHP, there was a greater accuracy in determining the importance of the indicators.

Through the results and findings of this study, more organizations can understand the potential of integrating Six Sigma and PM. It was just developed for the first two steps of the DMAIC cycle, and it is also a replicable method for any Six Sigma project where data acquisition through mining is possible.

The authors develop a fully applicable and understandable methodology which can be replicated in other settings and expanded in future research.

Process mining has emerged in the last decade as one of the most promising tools to discover and understand the actual execution of processes. This paper addresses the application of process mining techniques to analyze the performance of automatic guided vehicles (AGVs) in one of the Body in White circuits of the factory that Stellantis has in Vigo, Spain.

Standard process mining discovery and conformance algorithms are applied to analyze the different AGV execution paths, their lead times, main sources and identify any unexpected potential situations, such as unexpected paths or loops.

Results show that this method provides very useful insights which are not evident for logistics technicians. Even with such automated devices, where the room for decreased efficiency can be apparently small, process mining shows there are cases where unexpected situations occur, leading to an increase in circuit times and different variants for the same route, which pave the road for an actual improvement in performance and efficiency.

This paper provides evidence of the usefulness of applying process mining in manufacturing processes. Practical applications of process mining have traditionally been focused on processes related to services and management, such as order to cash and purchase to pay in enterprise resource planning software. Despite its potential for use in industrial manufacturing, such contributions are scarce in the current state of the art and, as far as we are aware of, do not fully justify its application.