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Article

Flavio Cesar Faria Fernandes, Moacir Godinho Filho and Maurice Bonney

The purpose of this paper is to present a practical proposal for integrating production control (PC) and quality control (QC) at the shop floor level.

Abstract

Purpose

The purpose of this paper is to present a practical proposal for integrating production control (PC) and quality control (QC) at the shop floor level.

Design/methodology/approach

The proposed method is based on three principles which relate PC and QC at the shop floor level. The proposal is applied successfully at the world's largest pencil factory.

Findings

The results show that the proposed method contributes to improve four performance indicators related to PC and QC at the company studied: increase the average throughput in about 28.9 per cent; reduce the average value of work in process (WIP) in about 35.6 per cent, reduce the average lead time by about 45.4 per cent, and reduce the average defect rate by about 71.4 per cent.

Research limitations/implications

The proposal (mainly because of principle III) is developed to be applied in repetitive production (RP) systems, i.e. environments characterized by low production volume and low product variety.

Practical implications

Some practical implications for industrial managers arises from this study: managers must consider the importance of integrated PC and QC functions in order to get better results concerning performance indicators such as throughput, WIP, lead time, and rejection rate; the materials flow simplification is a prerequisite for a lot of improvement initiatives at the shop floor level; the adequate choice of the production control system (PCS) is vital in order to get positive results regarding the performance indicators related to PC; the determination of the production pace (or rate) for a RP system must take account capacity restrictions and the influence of defect rate on production rate.

Originality/value

The paper is original in that it shows that the performance of the shop floor level can be improved by means of integrating PC and QC, by discussing and implementing a method which simplifies the material flow in the shop floor level, chooses the most adequate PCS and shows how the production rate influence on the rejection rate. Therefore, the paper is important for those which practice industrial management, more specifically on PC and QC functions.

Details

Industrial Management & Data Systems, vol. 109 no. 5
Type: Research Article
ISSN: 0263-5577

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Article

David Simons and Keivan Zokaei

Lean is a well‐established industrial paradigm and has proved to be of significant benefit in different sectors of the manufacturing industry (e.g. automotive and…

Abstract

Purpose

Lean is a well‐established industrial paradigm and has proved to be of significant benefit in different sectors of the manufacturing industry (e.g. automotive and aerospace). This paper aims to report on the introduction of lean to a new sector – the “UK red meat industry”. It highlights the benefits of lean production in one specific manufacturing area, the “cutting room”, where meat is split down from a carcass into retail cuts of meat.

Design/methodology/approach

A multiple case study approach is adopted in this paper. As part of the Red Meat Industry Forum's Value Chain Analysis Initiative, five cutting plants are presented as case studies in this paper.

Findings

This paper identifies two “traditional” and three “advanced” cutting rooms and reports a typical 25 per cent productivity gap. The paper tentatively concludes this is due to the advanced cases practicing lean techniques, such as “Takttime” and “work standardization”.

Originality/value

The literature review identifies a gap in previous research on the applications of logistics and operations management concepts and practices into the red meat industry. Particularly, lean techniques have been overlooked in the red meat industry.

Details

British Food Journal, vol. 107 no. 4
Type: Research Article
ISSN: 0007-070X

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Article

Abdelhakim Abdelhadi

The purpose of this paper is to investigate a lean manufacturing metric called Takt time as a benchmark evaluation measure to evaluate a public hospital’s service quality…

Abstract

Purpose

The purpose of this paper is to investigate a lean manufacturing metric called Takt time as a benchmark evaluation measure to evaluate a public hospital’s service quality. Lean manufacturing is an established managerial philosophy with a proven track record in industry. A lean metric called Takt time is applied as a measure to compare the relative efficiency between two emergency departments (EDs) belonging to the same public hospital. Outcomes guide managers to improve patient services and increase hospital performances.

Design/methodology/approach

The patient treatment lead time within the hospital’s two EDs (one department serves male and the other female patients) are the study’s focus. A lean metric called Takt time is used to find the service’s relative efficiency.

Findings

Findings show that the lean manufacturing metric called Takt time can be used as an effective way to measure service efficiency by analyzing relative efficiency and identifies bottlenecks in different departments providing the same services.

Originality/value

The paper presents a new procedure to compare relative efficiency between two EDs. It can be applied to any healthcare facility.

Details

International Journal of Health Care Quality Assurance, vol. 28 no. 5
Type: Research Article
ISSN: 0952-6862

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Article

Abdelhakim Abdelhadi

A lean manufacturing metric called Takt time is used as a benchmark evaluation measure to evaluate service quality at fast food restaurants. The metric is applied to find…

Abstract

Purpose

A lean manufacturing metric called Takt time is used as a benchmark evaluation measure to evaluate service quality at fast food restaurants. The metric is applied to find the relative efficiency between three fast food restaurants belonging to different chains. The purpose of this paper is to help guide management through ways to improve customer service and increase performance.

Design/methodology/approach

The customer lead time (the time taken by a customer from arrival at the service queue until their order is fulfilled) is the focus of this study. Takt time is used to find the relative efficiency of service time between three fast food restaurants.

Findings

It is shown that Takt time can be used effectively to measure the level of efficiency of the services provided. It measures the relative efficiency and identifies bottlenecks among different entities providing the same services.

Practical implications

The results can be used as a guide to rank the efficiency of the length of service time of different entities by taking the whole system into consideration rather than just measuring and comparing the service time itself between the entities. The results show the effectiveness of using lean manufacturing practices in pinpointing the relative inefficiencies between different service provider facilities.

Originality/value

This research presents a procedure to measure relative efficiency between different service providers to enhance their services. It can be applied to any service management systems that deal directly with walk-in customers.

Details

International Journal of Lean Six Sigma, vol. 7 no. 1
Type: Research Article
ISSN: 2040-4166

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Article

Patrick Pujo, Ilham El Khabous and Fouzia Ounnar

The aim of this research is to discuss the benefits of U-shaped layout for production cell operating in variable takt time. Different experiments were conducted using…

Abstract

Purpose

The aim of this research is to discuss the benefits of U-shaped layout for production cell operating in variable takt time. Different experiments were conducted using benchmarks to highlight the performance gap between a linear cell and a U-Cell.

Design/methodology/approach

The implementation of the production cell, either in a U-shaped or in a straight line layout, is optimized through linear programming based on the number of operators. The two corresponding programs, in Mosel language, use the same approach to not introduce bias in the comparison of results. The study used the authors’ own datasets and other well-known academic benchmarks.

Findings

A comparison was conducted between the obtained takt times, with equivalent operating conditions, in both U-Cell and linear cell. A significant increase of the production rate was observed. This increase has often exceeded 10 per cent, reaching 32 per cent. All the experiments show that, with the same number of operators, a cell in a U-shaped layout is always at least as efficient, in terms of attainable production rates, than an equivalent linear cell. Ninety-six per cent of the studied cases give an improvement of production rate. Moreover, the dispersion of the U-Cell results is weaker, which suggests that the U-shaped layout gives better performances in more robust manner.

Research limitations/implications

Results were obtained through a study of various academic benchmarks. The results must be validated on industrial situations.

Practical implications

This paper will be very useful for researchers and practitioners to understand lean implementations and their derived benefits. This paper will allow them to evaluate and analyze the expected benefits of the implementation of the production cell in the U-shaped layout (operating in variable takt time).

Originality/value

U-Cells constitute an appropriate solution for a layout of any kind of production cells with a variable structure (variability of the number of operators, of the organization of the cell, of the takt time […]). When facing a significant variation in the demand, the response consists of adjusting the number of operators assigned to the cell. This study jointly addresses the problem of the U-shaped layout and the operation in variable takt time.

Details

International Journal of Lean Six Sigma, vol. 6 no. 1
Type: Research Article
ISSN: 2040-4166

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Article

Abdelhakim Abdelhadi and Mwafak Shakoor

The purpose of this paper is to present a new approach to measure the service quality provided by a public health-care service provider using the lean manufacturing…

Abstract

Purpose

The purpose of this paper is to present a new approach to measure the service quality provided by a public health-care service provider using the lean manufacturing concept. The research shows that the adoption of lean manufacturing principles and methodologies may be used as a measure for efficiency. The relative efficiency measure concept is introduced.

Design/methodology/approach

The inpatient and outpatient pharmacies providing medicines to the public at a large regional hospital in the southern part of the Kingdom of Saudi Arabia were the focus of this study. The lean manufacturing concept is used as a method to improve the service quality and reduce the time needed to deliver the medicine by comparing the efficiency between these two pharmacies based on a metric used in lean manufacturing called takt time. A team was formed to study the current situation, and recommendations based on lean manufacturing were suggested for implementations.

Findings

The research shows that the adoption of lean manufacturing principles and methodologies may be used as an efficiency measure to compare between different departments working under the same managerial system.

Originality/value

The results presented in this paper are reliable, objective and may be generalized for measuring the relative performance efficiency between several departments providing the same type of services.

Details

Leadership in Health Services, vol. 27 no. 3
Type: Research Article
ISSN: 1751-1879

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Article

Sunil Kumar, Ashwani Dhingra and Bhim Singh

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…

Abstract

Purpose

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.

Design/methodology/approach

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.

Findings

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.

Originality/value

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.

Details

Journal of Engineering, Design and Technology, vol. 16 no. 1
Type: Research Article
ISSN: 1726-0531

Keywords

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Article

Saliha Karadayi Usta, Mehmet Kursat Oksuz and Mehmet Bulent Durmusoglu

This paper aims to propose a combined methodology to help decision makers in evaluating and selecting the most effective part feeding system.

Abstract

Purpose

This paper aims to propose a combined methodology to help decision makers in evaluating and selecting the most effective part feeding system.

Design/methodology/approach

As a first step of the methodology, a hierarchical clustering analysis is applied to design a kitting or hybrid feeding system. Second, activity-based costing methodology is applied to determine which system is better according to their costs. Besides, sensitivity analysis is implemented to observe the behavior of the system in case of the takt time changes.

Findings

Using kitting systems purely can lead to problems because of the big and expensive parts in the mixed-model assembly systems. Therefore, the hybrid feeding policy can provide better solutions for such systems.

Research limitations/implications

A case study is conducted in a company and the most produced product of the company is considered to design the part feeding system. Results indicated that transportation cost has a large proportion on the total cost and the hybrid feeding policy may be a good solution to reduce this cost.

Practical implications

The paper includes implications for the design of hybrid feeding systems in lean-based assembly lines. The proposed methodology may be a practical tool for decision makers to design and decide on the part feeding policy.

Originality/value

Kitting design has not been studied yet to the best of the authors’ knowledge. Besides, there is no certain decision methodology indicating which system is better. In this study, different methods are combined as a new methodology with the purpose of industrial decision-making.

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Article

Carlos Coutinho Fernandes Junior and Leonel Teixeira Pinto

The main purpose of this paper is to develop a study of the determination of the most appropriate execution steps, necessary for the construction of modelling, simulation…

Abstract

Purpose

The main purpose of this paper is to develop a study of the determination of the most appropriate execution steps, necessary for the construction of modelling, simulation and optimization for the specific area of slaughter line balancing. And through the developed model to demonstrate the application of simulation to increase productivity in a large-size swine slaughterhouse, focusing on operator stations balancing. The built model may be applied to support the management of the plant, allowing to evaluate and decide the optimized scenario that meets current needs considering operational cost, production demand and productivity.

Design/methodology/approach

For the research development, the selected software supports the characteristics of the evaluated process, in this case, a discreet simulation with stochastics variables. The studied plant was modelled door by door, from the swine reception until the packaging area. The research methodology was based on lean manufacturing (LM) principles, particularly in workstations balancing, by optimizing the idle time of the operators, comparing with the cycle time of each task, in the evaluated workstations.

Findings

The achieved result with the modelling and simulation was the increase of 11.89% in plant productivity through manpower optimization. The study indicates that the simulation applied with LM concepts as operative stations balancing and value stream map can be a very useful tool to support decision-making for productivity improvement.

Originality/value

This study approaches how modelling and simulation can support decision-making to implement improvements associated to workforce balancing optimization, especially in the studied area (agribusiness, animal slaughter). The studied process presents great variability associated with the processing time of each phase, making the analysis and modelling more complex. The number of workstations involved, with more than 800 employees, is an important point in the research, considering that cases with higher values than the case presented were not identified in literature.

Details

International Journal of Lean Six Sigma, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 2040-4166

Keywords

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Article

Ruth A. Kasul and Jaideep G. Motwani

Presents an application of the Toyota Production System (TPS) in a manufacturing environment. By means of a case study, discusses the most important elements of TPS, the…

Abstract

Presents an application of the Toyota Production System (TPS) in a manufacturing environment. By means of a case study, discusses the most important elements of TPS, the strategies used by the company for implementing TPS, and the significant benefits that were accrued in manufacturing operations and total inventory values. Obtains data through interviews, questionnaire survey and archival sources.

Details

Industrial Management & Data Systems, vol. 97 no. 7
Type: Research Article
ISSN: 0263-5577

Keywords

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