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Article
Publication date: 15 April 2024

Joici Mendonça Muniz Gomes, Rodrigo Goyannes Gusmão Caiado, Taciana Mareth, Renan Silva Santos and Luiz Felipe Scavarda

To address the absence of Lean in transportation logistics in the digital era, this study aims to investigate the application of Lean transportation (LT) tools to reduce waste and…

Abstract

Purpose

To address the absence of Lean in transportation logistics in the digital era, this study aims to investigate the application of Lean transportation (LT) tools to reduce waste and facilitate the digital transformation of dedicated road transportation in the offshore industry.

Design/methodology/approach

The study adopts action research with a multimethod approach, including a scoping review, focus groups (FG) and participant observation. The research is conducted within the offshore supply chain of a major oil and gas company.

Findings

Implementing LT’s continuous improvement tools, particularly value stream mapping (VSM), reduces offshore transportation waste and provides empirical evidence about the intersection of Lean and digital technologies. Applying techniques drawn from organisational learning theory (OLT), stakeholders involved in VSM mapping and FGs engage in problem-solving and develop action plans, driving digital transformation. Waste reduction in loading and unloading stages leads to control actions, automation and process improvements, significantly reducing downtime. This results in an annual monetary gain of US$1.3m. The study also identifies waste related to human effort and underutilised digital resources.

Originality/value

This study contributes to theory and practice by using action research and LT techniques in a real intervention case. From the lens of OLT, it highlights the potential of LT tools for digital transformation and demonstrates the convergence of waste reduction through Lean and Industry 4.0 technologies in the offshore supply chain. Practical outputs, including a benchmarking questionnaire and a plan-do-check-act cycle, are provided for other companies in the same industry segment.

Details

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

Keywords

Article
Publication date: 27 March 2024

Temesgen Agazhie and Shalemu Sharew Hailemariam

This study aims to quantify and prioritize the main causes of lean wastes and to apply reduction methods by employing better waste cause identification methodologies.

Abstract

Purpose

This study aims to quantify and prioritize the main causes of lean wastes and to apply reduction methods by employing better waste cause identification methodologies.

Design/methodology/approach

We employed fuzzy techniques for order preference by similarity to the ideal solution (FTOPSIS), fuzzy analytical hierarchy process (FAHP), and failure mode effect analysis (FMEA) to determine the causes of defects. To determine the current defect cause identification procedures, time studies, checklists, and process flow charts were employed. The study focuses on the sewing department of a clothing industry in Addis Ababa, Ethiopia.

Findings

These techniques outperform conventional techniques and offer a better solution for challenging decision-making situations. Each lean waste’s FMEA criteria, such as severity, occurrence, and detectability, were examined. A pairwise comparison revealed that defect has a larger effect than other lean wastes. Defects were mostly caused by inadequate operator training. To minimize lean waste, prioritizing their causes is crucial.

Research limitations/implications

The research focuses on a case company and the result could not be generalized for the whole industry.

Practical implications

The study used quantitative approaches to quantify and prioritize the causes of lean waste in the garment industry and provides insight for industrialists to focus on the waste causes to improve their quality performance.

Originality/value

The methodology of integrating FMEA with FAHP and FTOPSIS was the new contribution to have a better solution to decision variables by considering the severity, occurrence, and detectability of the causes of wastes. The data collection approach was based on experts’ focus group discussion to rate the main causes of defects which could provide optimal values of defect cause prioritization.

Details

International Journal of Quality & Reliability Management, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 0265-671X

Keywords

Article
Publication date: 11 January 2024

Maria Luiza de Souza Morato and Karine Araujo Ferreira

The pupose of this study is to systematically review the current literature on the value stream mapping (VSM) application in the construction industry to investigate the evolution…

Abstract

Purpose

The pupose of this study is to systematically review the current literature on the value stream mapping (VSM) application in the construction industry to investigate the evolution observed over time and the results obtained by adopting this tool. In addition, special attention was given to the potential of VSM in identifying loss and waste, as well as their main causes.

Design/methodology/approach

The study analyses papers in literature using Preferred Reporting Items for Systematic Reviews and Meta-Analyses research protocol. As a result, 383 papers were initially identified, and 47 papers were selected.

Findings

It was observed that the number of studies addressing this topic has been increasing over the past decade and findings related to the evolution, application and the benefits obtained from the VSM application in context of construction were presented. Additionally, the authors found that the two most cited lean wastes were waiting and defects in the production chain. The main causes of this waste and loss were also identified in this work.

Practical implications

This paper contributes by presenting the applicability of VSM as a tool in the construction as found in the literature. For academics, it will be possible to clearly observe research gaps and for industry managers, to identify the main sources of waste and assess the performance of the tool’s application.

Originality/value

The study uses a systematic review to analyze the application of the VSM tool in the construction industry and provides guidance for future research by identifying research gaps, in addition to conducting an extensive analysis of the tool’s potential in waste identification in the studied papers and their primary causes.

Details

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

Keywords

Article
Publication date: 16 November 2023

Felix Preshanth Santhiapillai and R.M. Chandima Ratnayake

The purpose of this study is to investigate the integrated application of business process modeling and notation (BPMN) and value stream mapping (VSM) to improve knowledge work…

Abstract

Purpose

The purpose of this study is to investigate the integrated application of business process modeling and notation (BPMN) and value stream mapping (VSM) to improve knowledge work performance and productivity in police services. In order to explore the application of the hybrid BPMN-VSM approach in police services, this study uses the department of digital crime investigation (DCI) in one Norwegian police district as a case study.

Design/methodology/approach

Service process identification was the next step after selecting an appropriate organizational unit for the case study. BPMN-VSM-based current state mapping, including time and waste analyses, was used to determine cycle and lead time and identify value-adding and nonvalue-adding activities. Subsequently, improvement opportunities were identified, and the current state process was re-designed and constructed through future state mapping.

Findings

The study results indicate a 44.4% and 83.0% reduction in process cycle and lead time, respectively. This promising result suggests that the hybrid BPMN-VSM approach can support the visualization of bottlenecks and possible causes of increased lead times, followed by the systematic identification and proposals of avenues for future improvement and innovation to remedy the discovered inefficiencies in a complex knowledge-work environment.

Research limitations/implications

This study focused on one department in a Norwegian police district. However, the experience gained can support researchers and practitioners in understanding lean implementation through an integrated BPMN and VSM model, offering a unique insight into the ability to investigate complex systems.

Originality/value

Complex knowledge work processes generally characterize police services due to a high number of activities, resources and stakeholder involvement. Implementing lean thinking in this context is significantly challenging, and the literature on this topic is limited. This study addresses the applicability of the hybrid BPMN-VSM approach in police services with an original public sector case study in Norway.

Details

International Journal of Productivity and Performance Management, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1741-0401

Keywords

Article
Publication date: 12 February 2024

Ivo Hristov, Matteo Cristofaro, Riccardo Camilli and Luna Leoni

This paper aims to (1) identify the different performance drivers (lead indicators) and outcome measures (lag indicators) investigated in the literature concerning the four…

Abstract

Purpose

This paper aims to (1) identify the different performance drivers (lead indicators) and outcome measures (lag indicators) investigated in the literature concerning the four balanced scorecard (BSC) perspectives in operations management (OM) contexts and (2) understand how performance drivers and outcome measures (and substantiated perspectives) are related.

Design/methodology/approach

We undertake a systematic literature review of the BSC literature in OM journals. From the final sample of 40 articles, performance drivers and outcome measures have been identified, and the relationships amongst them have been synthesised according to the system dynamics approach.

Findings

Findings show (1) the most relevant performance drivers and outcome measures within each BSC perspective, (2) their relationships, (3) how the perspectives are linked through the performance drivers and outcome measures and (4) how the different measures relate systemically. Accordingly, four causal loops amongst identified measures have been built, which – jointly considered – allowed for the creation of a dynamic strategy map for OM.

Originality/value

This study is the first one that provides a comprehensive and holistic view of how the different performance drivers and outcome measures within and between the four BSC perspectives in OM relate systemically, increasing the knowledge and understanding of scholars and practitioners.

Details

Journal of Manufacturing Technology Management, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 24 August 2023

Nasser Zaky, Mohamed Zaky Ahmed, Ali Alarjani and El-Awady Attia

This study aims to improve the market competitiveness of iron and steel manufacturers in developing countries by reducing their production costs.

Abstract

Purpose

This study aims to improve the market competitiveness of iron and steel manufacturers in developing countries by reducing their production costs.

Design/methodology/approach

The research methodology relies on a case study-based approach. The study relies on six steps. The first is the preparation, then the five steps of the six-sigma – define, measure, analyze, improve, control. The qualitative and quantitative data were considered. The qualitative analysis relies on the experts’ judgment of internal status. The quantitative analysis uses the job floor data from three iron and steel manufacturers. After collecting, screening and analyzing the data, the root causes of the different wastes were identified that increase production costs. Consequently, lean manufacturing principles and tools are identified and prioritized using the decision-making trial and evaluation laboratory method, and then implemented to reduce the different types of waste.

Findings

The main wastes are related to inventory, time, quality and workforce. The lean tools were proposed with the implementation plan for the discovered root causes. The performance was monitored during and after the implementation of the lean initiatives in one of the three companies. The obtained results showed an increase in some performance indicators such as throughput (70.6%), revenue from by-products (459%), inventory turnover (54%), operation availability (45%), and plant availability (41%). On the other hand, results showed a decrease of time delay (78%), man-hour/ton (52.4%) and downgraded products (63.3%).

Practical implications

The current case study findings can be utilized by Iron and Steel factories at the developing countries. In addition, the proposed lean implementation methodology can be adopted for any other industries.

Social implications

The current work introduces an original and practical road map to implement the lean six-sigma body of knowledge in the iron and steel manufacturers.

Originality/value

This work introduces an effective and practical case study-based approach to implementing the lean six-sigma body of knowledge in the iron and steel manufacturers in one of the underdevelopment countries. The consideration of the opinion of the different engineers from different sectors shows significant identification of the major problems in the manufacturing and utility sectors that lead to significant performance improvement after solving them.

Details

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

Keywords

Article
Publication date: 19 February 2024

Manjeet Kharub, Himanshu Gupta, Sudhir Rana and Olivia McDermott

The objective of this study is to systematically identify, categorize and assess the driving factors and interdependencies associated with various types of healthcare waste. The…

Abstract

Purpose

The objective of this study is to systematically identify, categorize and assess the driving factors and interdependencies associated with various types of healthcare waste. The study specifically focuses on waste that has been managed or is recommended for treatment through the application of Lean Six Sigma (LSS) methodologies.

Design/methodology/approach

To accomplish the study’s objectives, interpretive structural modeling (ISM) was utilized. This analytical tool aided in quantifying the driving power and dependencies of each form of healthcare waste, referred to as “enablers,” as well as their related variables. As a result, these enablers were classified into four distinct categories: autonomous, dependent, linkage and drivers or independents.

Findings

In the healthcare sector, the “high cost” (HC) emerges as an autonomous variable, operating with substantial independence. Conversely, variables such as skill wastage, poor service quality and low patient satisfaction are identified as dependent variables. These are distinguished by their low driving power and high dependency. On the flip side, variables related to transportation, production, processing and defect waste manifest strong driving forces and minimal dependencies, categorizing them as independent factors. Notably, inventory waste (IW) is highlighted as a salient issue within the healthcare domain, given its propensity to engender additional forms of waste.

Research limitations/implications

Employing the ISM model, along with comprehensive case study analyses, provides a detailed framework for examining the complex hierarchies of waste existing within the healthcare sector. This methodological approach equips healthcare leaders with the tools to accurately pinpoint and eliminate unnecessary expenditures, thereby optimizing operational efficiency and enhancing patient satisfaction. Of particular significance, the study calls attention to the key role of IW, which often acts as a trigger for other forms of waste in the sector, thus identifying a crucial area requiring focused intervention and improvement.

Originality/value

This research reveals new insights into how waste variables are structured in healthcare, offering a useful guide for managers looking to make their waste-reduction strategies more efficient. These insights are highly relevant not just for healthcare providers but also for the administrators and researchers who are helping to shape the industry. Using the classification and ranking model developed in this study, healthcare organizations can more easily spot and address common types of waste. In addition, the model serves as a useful tool for practitioners, helping them gain a deeper, more detailed understanding of how different factors are connected in efforts to reduce waste.

Details

International Journal of Quality & Reliability Management, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 0265-671X

Keywords

Article
Publication date: 15 August 2023

Imnatila Pongen, Pritee Ray and Rohit Gupta

Rapid innovation and developments in personal electronic technology have encouraged users to change users' devices more frequently than ever, which has resulted in creating a…

Abstract

Purpose

Rapid innovation and developments in personal electronic technology have encouraged users to change users' devices more frequently than ever, which has resulted in creating a massive increase in the amount of electronic waste. The study focuses on identifying the barriers to closed-loop supply chain (CLSC) in the electronic industry.

Design/methodology/approach

A framework for analyzing the relationships among CLSC adoption barriers is designed. The authors adopted the decision-making trial and evaluation laboratory (DEMATEL) technique to determine the critical barriers of electronic CLSC from the opinion of experts in the field.

Findings

The outcome from the analysis suggests that cost barriers, financial barrier, process barriers and supplier-side barriers are the main causal factors that prevent the adoption and implementation of e-waste CLSC. The causal relationship indicates that financial barrier is the most influential factor, while phycological barrier is the most flexible barrier to the adoption of e-waste CLSC.

Research limitations/implications

This study is restricted to CLSC adoption barriers in the electronic industry by evaluating 36 sub-barriers grouped into 8 main dimensions related to different members of the supply chain.

Practical implications

Closed-loop adoption barriers have been proposed to understand the crucial barriers to implementation of CLSC in the electronic industry. The cause-and-effect relationship indicates the critical factors to be improved to increase adoption of e-waste CLSC, helping managers and regulatory bodies to mitigate the problem areas.

Originality/value

This study contributes to the literature on CLSC by adopting a multi-criteria decision-making (MCDM) technique which captures the critical barriers of e-waste CLSC adoption in Indian scenario.

Details

Benchmarking: An International Journal, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1463-5771

Keywords

Article
Publication date: 2 April 2024

R.S. Vignesh and M. Monica Subashini

An abundance of techniques has been presented so forth for waste classification but, they deliver inefficient results with low accuracy. Their achievement on various repositories…

Abstract

Purpose

An abundance of techniques has been presented so forth for waste classification but, they deliver inefficient results with low accuracy. Their achievement on various repositories is different and also, there is insufficiency of high-scale databases for training. The purpose of the study is to provide high security.

Design/methodology/approach

In this research, optimization-assisted federated learning (FL) is introduced for thermoplastic waste segregation and classification. The deep learning (DL) network trained by Archimedes Henry gas solubility optimization (AHGSO) is used for the classification of plastic and resin types. The deep quantum neural networks (DQNN) is used for first-level classification and the deep max-out network (DMN) is employed for second-level classification. This developed AHGSO is obtained by blending the features of Archimedes optimization algorithm (AOA) and Henry gas solubility optimization (HGSO). The entities included in this approach are nodes and servers. Local training is carried out depending on local data and updations to the server are performed. Then, the model is aggregated at the server. Thereafter, each node downloads the global model and the update training is executed depending on the downloaded global and the local model till it achieves the satisfied condition. Finally, local update and aggregation at the server is altered based on the average method. The Data tag suite (DATS_2022) dataset is used for multilevel thermoplastic waste segregation and classification.

Findings

By using the DQNN in first-level classification the designed optimization-assisted FL has gained an accuracy of 0.930, mean average precision (MAP) of 0.933, false positive rate (FPR) of 0.213, loss function of 0.211, mean square error (MSE) of 0.328 and root mean square error (RMSE) of 0.572. In the second level classification, by using DMN the accuracy, MAP, FPR, loss function, MSE and RMSE are 0.932, 0.935, 0.093, 0.068, 0.303 and 0.551.

Originality/value

The multilevel thermoplastic waste segregation and classification using the proposed model is accurate and improves the effectiveness of the classification.

Article
Publication date: 28 March 2024

Elisa Gonzalez Santacruz, David Romero, Julieta Noguez and Thorsten Wuest

This research paper aims to analyze the scientific and grey literature on Quality 4.0 and zero-defect manufacturing (ZDM) frameworks to develop an integrated quality 4.0 framework…

Abstract

Purpose

This research paper aims to analyze the scientific and grey literature on Quality 4.0 and zero-defect manufacturing (ZDM) frameworks to develop an integrated quality 4.0 framework (IQ4.0F) for quality improvement (QI) based on Six Sigma and machine learning (ML) techniques towards ZDM. The IQ4.0F aims to contribute to the advancement of defect prediction approaches in diverse manufacturing processes. Furthermore, the work enables a comprehensive analysis of process variables influencing product quality with emphasis on the use of supervised and unsupervised ML techniques in Six Sigma’s DMAIC (Define, Measure, Analyze, Improve and Control) cycle stage of “Analyze.”

Design/methodology/approach

The research methodology employed a systematic literature review (SLR) based on PRISMA guidelines to develop the integrated framework, followed by a real industrial case study set in the automotive industry to fulfill the objectives of verifying and validating the proposed IQ4.0F with primary data.

Findings

This research work demonstrates the value of a “stepwise framework” to facilitate a shift from conventional quality management systems (QMSs) to QMSs 4.0. It uses the IDEF0 modeling methodology and Six Sigma’s DMAIC cycle to structure the steps to be followed to adopt the Quality 4.0 paradigm for QI. It also proves the worth of integrating Six Sigma and ML techniques into the “Analyze” stage of the DMAIC cycle for improving defect prediction in manufacturing processes and supporting problem-solving activities for quality managers.

Originality/value

This research paper introduces a first-of-its-kind Quality 4.0 framework – the IQ4.0F. Each step of the IQ4.0F was verified and validated in an original industrial case study set in the automotive industry. It is the first Quality 4.0 framework, according to the SLR conducted, to utilize the principal component analysis technique as a substitute for “Screening Design” in the Design of Experiments phase and K-means clustering technique for multivariable analysis, identifying process parameters that significantly impact product quality. The proposed IQ4.0F not only empowers decision-makers with the knowledge to launch a Quality 4.0 initiative but also provides quality managers with a systematic problem-solving methodology for quality improvement.

Details

The TQM Journal, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1754-2731

Keywords

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