Pub Date : 2023-06-20DOI: 10.1108/ijlss-10-2021-0176
A. Mohammad, A. Hamja, P. Hasle
Purpose Shorter lead time with low price and quality product demand is pivotal in the garment industry. Pressure on production lead time stresses the importance of reducing style changeover time in manufacturing factories, and this paper aims to contribute to solving the challenge by showing how the single minute exchange of die (SMED) methodology in practice can be adapted to garment factories in developing countries. Design/methodology/approach The paper investigates three cases of SMED implementation integrated with responsible, accountable, consulted, informed (RACI) matrices in garment factories in an action research approach. Both quantitative and qualitative methods are applied. Findings The study shows a reduction of 50% to 64% of changeover time with SMED implementation measured with two key indicators – throughout time and time to reach peak production. Moreover, the implementation depends on the application of the RACI matrix for the distribution of responsibility as well as integration with the basic production flow before and after the application of SMED. Practical implications The study can guide better SMED implementation in garment factories with limited investment by stressing the need to adapt to the specifics of the garment industry, secure the division of responsibility and integrate SMED in the production flow before and after the changeover. Originality/value Limited research on the application of SMED in the garment industry. This paper contributes to understanding the specific conditions for successful implementation in the garment industry in developing countries and addresses additional activities that help secure a sustainable implementation process.
{"title":"Reduction of changeover time through SMED with RACI integration in garment factories","authors":"A. Mohammad, A. Hamja, P. Hasle","doi":"10.1108/ijlss-10-2021-0176","DOIUrl":"https://doi.org/10.1108/ijlss-10-2021-0176","url":null,"abstract":"Purpose\u0000Shorter lead time with low price and quality product demand is pivotal in the garment industry. Pressure on production lead time stresses the importance of reducing style changeover time in manufacturing factories, and this paper aims to contribute to solving the challenge by showing how the single minute exchange of die (SMED) methodology in practice can be adapted to garment factories in developing countries.\u0000\u0000\u0000Design/methodology/approach\u0000The paper investigates three cases of SMED implementation integrated with responsible, accountable, consulted, informed (RACI) matrices in garment factories in an action research approach. Both quantitative and qualitative methods are applied.\u0000\u0000\u0000Findings\u0000The study shows a reduction of 50% to 64% of changeover time with SMED implementation measured with two key indicators – throughout time and time to reach peak production. Moreover, the implementation depends on the application of the RACI matrix for the distribution of responsibility as well as integration with the basic production flow before and after the application of SMED.\u0000\u0000\u0000Practical implications\u0000The study can guide better SMED implementation in garment factories with limited investment by stressing the need to adapt to the specifics of the garment industry, secure the division of responsibility and integrate SMED in the production flow before and after the changeover.\u0000\u0000\u0000Originality/value\u0000Limited research on the application of SMED in the garment industry. This paper contributes to understanding the specific conditions for successful implementation in the garment industry in developing countries and addresses additional activities that help secure a sustainable implementation process.","PeriodicalId":48601,"journal":{"name":"International Journal of Lean Six Sigma","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-06-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42276433","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-06-19DOI: 10.1108/ijlss-03-2021-0047
Carlos Gastelum-Acosta, Jorge Limón-Romero, Y. Baez-López, Diego A. Tlapa, J. García-Alcaráz, Cesar Puente, Armando Perez-Sanchez
Purpose This paper aims to identify the relationships among critical success factors (CSFs) for lean six sigma (LSS) implementation in higher education institutions (HEIs). Design/methodology/approach An extensive literature review was conducted to design the survey instrument, which the authors later administered in Mexican public HEIs to identify the existing relationships among the CSFs and their impact on the benefits obtained from implementing LSS projects. The data were empirically and statistically validated using exploratory and confirmatory factor analysis. Additionally, the authors applied the structural equation modeling (SEM) technique on SPSS Amos to validate the nine hypotheses supporting the research. Findings The results suggest that the success of LSS projects in HEIs is highly bound to a serious commitment from top management and several interrelated factors. Research limitations/implications The main limitations of the study are that the research is cross-sectional in nature and regional in focus. Namely, the data used to validate the structural model were gathered from a small representative subset of the study population – i.e. Mexican public HEIs – and at a specific point in time. Practical implications The results reported here represent a reference framework for HEIs worldwide that wish to continuously improve their processes through LSS improvement projects. Originality/value This study proposes a statistically validated model using the SEM technique that depicts the relationships among LSS CSFs in HEIs.
{"title":"Modeling critical success factors of lean six sigma in higher education institutions","authors":"Carlos Gastelum-Acosta, Jorge Limón-Romero, Y. Baez-López, Diego A. Tlapa, J. García-Alcaráz, Cesar Puente, Armando Perez-Sanchez","doi":"10.1108/ijlss-03-2021-0047","DOIUrl":"https://doi.org/10.1108/ijlss-03-2021-0047","url":null,"abstract":"\u0000Purpose\u0000This paper aims to identify the relationships among critical success factors (CSFs) for lean six sigma (LSS) implementation in higher education institutions (HEIs).\u0000\u0000\u0000Design/methodology/approach\u0000An extensive literature review was conducted to design the survey instrument, which the authors later administered in Mexican public HEIs to identify the existing relationships among the CSFs and their impact on the benefits obtained from implementing LSS projects. The data were empirically and statistically validated using exploratory and confirmatory factor analysis. Additionally, the authors applied the structural equation modeling (SEM) technique on SPSS Amos to validate the nine hypotheses supporting the research.\u0000\u0000\u0000Findings\u0000The results suggest that the success of LSS projects in HEIs is highly bound to a serious commitment from top management and several interrelated factors.\u0000\u0000\u0000Research limitations/implications\u0000The main limitations of the study are that the research is cross-sectional in nature and regional in focus. Namely, the data used to validate the structural model were gathered from a small representative subset of the study population – i.e. Mexican public HEIs – and at a specific point in time.\u0000\u0000\u0000Practical implications\u0000The results reported here represent a reference framework for HEIs worldwide that wish to continuously improve their processes through LSS improvement projects.\u0000\u0000\u0000Originality/value\u0000This study proposes a statistically validated model using the SEM technique that depicts the relationships among LSS CSFs in HEIs.\u0000","PeriodicalId":48601,"journal":{"name":"International Journal of Lean Six Sigma","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-06-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42880906","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-05-19DOI: 10.1108/ijlss-06-2022-0140
P. Tsarouhas, Niki N. Sidiropoulou
Purpose In a packaging olives manufacturing system, the drained weight of the product plays a decisive role in customer’s satisfaction as well as in financial saving for the organization. The purpose of this study is to minimize the variation of the drained weight of olives in the production system to avoid the negative consequences. Design/methodology/approach The research develops a practical implementation step-by-step of Six Sigma define, measure, analyze, improve and control (DMAIC) in reducing the variation of the drained weight of olives. Findings Data analysis was used at various phases of the project to identify the root causes of rejection and rework. As a result of the necessary interventions and actions to optimize the manufacturing process, the standard deviation of drained weight was significantly reduced by 51.02%, with a 99.97% decrease in the number of parts per million defectives. Thus, the yield of the production process was improved by 8.24%. The estimated annual savings from this project were US$ 228,000 resulting from reduced rejection and rework. Practical implications This research may be used in packaging olives production systems as a tool for managers and engineers planning to increase productivity and efficiency while also improving product quality. The study also provided the organization with helpful actions that will be used to guide future Six Sigma operations management on the system. Thus, practical guidelines and solutions are provided. Originality/value In this project, for the first time, the Six Sigma methodology has been applied to solve a real-world problem in the packaging olives manufacturing system and to show that the DMAIC approach may assist to improve the efficiency of their operations and hence contribute to their quest toward continuous improvement.
{"title":"Application of Six Sigma methodology using DMAIC approach for a packaging olives production system: a case study","authors":"P. Tsarouhas, Niki N. Sidiropoulou","doi":"10.1108/ijlss-06-2022-0140","DOIUrl":"https://doi.org/10.1108/ijlss-06-2022-0140","url":null,"abstract":"\u0000Purpose\u0000In a packaging olives manufacturing system, the drained weight of the product plays a decisive role in customer’s satisfaction as well as in financial saving for the organization. The purpose of this study is to minimize the variation of the drained weight of olives in the production system to avoid the negative consequences.\u0000\u0000\u0000Design/methodology/approach\u0000The research develops a practical implementation step-by-step of Six Sigma define, measure, analyze, improve and control (DMAIC) in reducing the variation of the drained weight of olives.\u0000\u0000\u0000Findings\u0000Data analysis was used at various phases of the project to identify the root causes of rejection and rework. As a result of the necessary interventions and actions to optimize the manufacturing process, the standard deviation of drained weight was significantly reduced by 51.02%, with a 99.97% decrease in the number of parts per million defectives. Thus, the yield of the production process was improved by 8.24%. The estimated annual savings from this project were US$ 228,000 resulting from reduced rejection and rework.\u0000\u0000\u0000Practical implications\u0000This research may be used in packaging olives production systems as a tool for managers and engineers planning to increase productivity and efficiency while also improving product quality. The study also provided the organization with helpful actions that will be used to guide future Six Sigma operations management on the system. Thus, practical guidelines and solutions are provided.\u0000\u0000\u0000Originality/value\u0000In this project, for the first time, the Six Sigma methodology has been applied to solve a real-world problem in the packaging olives manufacturing system and to show that the DMAIC approach may assist to improve the efficiency of their operations and hence contribute to their quest toward continuous improvement.\u0000","PeriodicalId":48601,"journal":{"name":"International Journal of Lean Six Sigma","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-05-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45520604","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-05-19DOI: 10.1108/ijlss-07-2022-0165
M. Katsigiannis, Minas Pantelidakis, K. Mykoniatis
Purpose With hybrid simulation techniques getting popular for systems improvement in multiple fields, this study aims to provide insight on the use of hybrid simulation to assess the effect of lean manufacturing (LM) techniques on manufacturing facilities and the transition of a mass production (MP) facility to incorporating LM techniques. Design/methodology/approach In this paper, the authors apply a hybrid simulation approach to improve an educational automotive assembly line and provide guidelines for implementing different LM techniques. Specifically, the authors describe the design, development, verification and validation of a hybrid discrete-event and agent-based simulation model of a LEGO® car assembly line to analyze, improve and assess the system’s performance. The simulation approach examines the base model (MP) and an alternative scenario (just-in-time [JIT] with Heijunka). Findings The hybrid simulation approach effectively models the facility. The alternative simulation scenario (implementing JIT and Heijunka LM techniques) improved all examined performance metrics. In more detail, the system’s lead time was reduced by 47.37%, the throughput increased by 5.99% and the work-in-progress for workstations decreased by up to 56.73%. Originality/value This novel hybrid simulation approach provides insight and can be potentially extrapolated to model other manufacturing facilities and evaluate transition scenarios from MP to LM.
{"title":"Assessing the transition from mass production to lean manufacturing using a hybrid simulation model of a LEGO® automotive assembly line","authors":"M. Katsigiannis, Minas Pantelidakis, K. Mykoniatis","doi":"10.1108/ijlss-07-2022-0165","DOIUrl":"https://doi.org/10.1108/ijlss-07-2022-0165","url":null,"abstract":"\u0000Purpose\u0000With hybrid simulation techniques getting popular for systems improvement in multiple fields, this study aims to provide insight on the use of hybrid simulation to assess the effect of lean manufacturing (LM) techniques on manufacturing facilities and the transition of a mass production (MP) facility to incorporating LM techniques.\u0000\u0000\u0000Design/methodology/approach\u0000In this paper, the authors apply a hybrid simulation approach to improve an educational automotive assembly line and provide guidelines for implementing different LM techniques. Specifically, the authors describe the design, development, verification and validation of a hybrid discrete-event and agent-based simulation model of a LEGO® car assembly line to analyze, improve and assess the system’s performance. The simulation approach examines the base model (MP) and an alternative scenario (just-in-time [JIT] with Heijunka).\u0000\u0000\u0000Findings\u0000The hybrid simulation approach effectively models the facility. The alternative simulation scenario (implementing JIT and Heijunka LM techniques) improved all examined performance metrics. In more detail, the system’s lead time was reduced by 47.37%, the throughput increased by 5.99% and the work-in-progress for workstations decreased by up to 56.73%.\u0000\u0000\u0000Originality/value\u0000This novel hybrid simulation approach provides insight and can be potentially extrapolated to model other manufacturing facilities and evaluate transition scenarios from MP to LM.\u0000","PeriodicalId":48601,"journal":{"name":"International Journal of Lean Six Sigma","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-05-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45729229","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-05-18DOI: 10.1108/ijlss-07-2022-0156
Anna Trubetskaya, A. Ryan, Frank Murphy
Purpose This paper aims to introduce a model using a digital twin concept in a cold heading manufacturing and develop a digital visual management (VM) system using Lean overall equipment effectiveness (OEE) tool to enhance the process performance and establish Fourth Industrial Revolution (I4.0) platform in small and medium enterprises (SMEs). Design/methodology/approach This work utilised plan, do, check, act Lean methodology to create a digital twin of each machine in a smart manufacturing facility by taking the Lean tool OEE and digitally transforming it in the context of I4.0. To demonstrate the effectiveness of process digitisation, a case study was carried out at a manufacturing department to provide the data to the model and later validate synergy between Lean and I4.0 platform. Findings The OEE parameter can be increased by 10% using a proposed digital twin model with the introduction of a Level 0 into VM platform to clearly define the purpose of each data point gathered further replicate in projects across the value stream. Research limitations/implications The findings suggest that researchers should look beyond conversion of stored data into visualisations and predictive analytics to improve the model connectivity. The development of strong big data analytics capabilities in SMEs can be achieved by shortening the time between data gathering and impact on the model performance. Originality/value The novelty of this study is the application of OEE Lean tool in the smart manufacturing sector to allow SME organisations to introduce digitalisation on the back of structured and streamlined principles with well-defined end goals to reach the optimal OEE.
{"title":"An implementation model for digitisation of visual management to develop a smart manufacturing process","authors":"Anna Trubetskaya, A. Ryan, Frank Murphy","doi":"10.1108/ijlss-07-2022-0156","DOIUrl":"https://doi.org/10.1108/ijlss-07-2022-0156","url":null,"abstract":"\u0000Purpose\u0000This paper aims to introduce a model using a digital twin concept in a cold heading manufacturing and develop a digital visual management (VM) system using Lean overall equipment effectiveness (OEE) tool to enhance the process performance and establish Fourth Industrial Revolution (I4.0) platform in small and medium enterprises (SMEs).\u0000\u0000\u0000Design/methodology/approach\u0000This work utilised plan, do, check, act Lean methodology to create a digital twin of each machine in a smart manufacturing facility by taking the Lean tool OEE and digitally transforming it in the context of I4.0. To demonstrate the effectiveness of process digitisation, a case study was carried out at a manufacturing department to provide the data to the model and later validate synergy between Lean and I4.0 platform.\u0000\u0000\u0000Findings\u0000The OEE parameter can be increased by 10% using a proposed digital twin model with the introduction of a Level 0 into VM platform to clearly define the purpose of each data point gathered further replicate in projects across the value stream.\u0000\u0000\u0000Research limitations/implications\u0000The findings suggest that researchers should look beyond conversion of stored data into visualisations and predictive analytics to improve the model connectivity. The development of strong big data analytics capabilities in SMEs can be achieved by shortening the time between data gathering and impact on the model performance.\u0000\u0000\u0000Originality/value\u0000The novelty of this study is the application of OEE Lean tool in the smart manufacturing sector to allow SME organisations to introduce digitalisation on the back of structured and streamlined principles with well-defined end goals to reach the optimal OEE.\u0000","PeriodicalId":48601,"journal":{"name":"International Journal of Lean Six Sigma","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-05-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49043568","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Purpose Environmental sustainability is quickly becoming one of the most critical issues in industry development. This study aims to conduct a systematic literature review through which the author can provide various research areas to work on for future researchers and provide insight into Industry 4.0 and environmental sustainability. Design/methodology/approach This study accomplishes this by performing a backward analysis using text mining on the Scopus database. Latent semantic analysis (LSA) was used to analyze the corpus of 4,364 articles published between 2013 and 2023. The authors generated ten clusters using keywords in the industrial revolution and environmental sustainability domain, highlighting ten research avenues for further exploration. Findings In this study, three research questions discuss the role of environmental sustainability with Industry 4.0. The author predicted ten clusters treated as recent trends on which more insight is required from future researchers. The authors provided year-wise analysis, top authors, top countries, top sources and network analysis related to the topic. Finally, the study provided industrialization’s effect on environmental sustainability and the future aspect of automation. Research limitations/implications The reliability of the current study may be compromised, notwithstanding the size of the sample used. Poor retrieval of the literature corpus can be attributed to the limitations imposed by the search words, synonyms, string construction and variety of search engines used, as well as to the accurate exclusion of results for which the search string is insufficient. Originality/value This research is the first-ever study in which a natural language processing technique is implemented to predict future research areas based on the keywords–document relationship.
{"title":"Industrial revolution and environmental sustainability: an analytical interpretation of research constituents in Industry 4.0","authors":"Arun Malik, Shamneesh Sharma, Isha Batra, Chetan Sharma, Mahender Singh Kaswan, J. Garza‐Reyes","doi":"10.1108/ijlss-02-2023-0030","DOIUrl":"https://doi.org/10.1108/ijlss-02-2023-0030","url":null,"abstract":"\u0000Purpose\u0000Environmental sustainability is quickly becoming one of the most critical issues in industry development. This study aims to conduct a systematic literature review through which the author can provide various research areas to work on for future researchers and provide insight into Industry 4.0 and environmental sustainability.\u0000\u0000\u0000Design/methodology/approach\u0000This study accomplishes this by performing a backward analysis using text mining on the Scopus database. Latent semantic analysis (LSA) was used to analyze the corpus of 4,364 articles published between 2013 and 2023. The authors generated ten clusters using keywords in the industrial revolution and environmental sustainability domain, highlighting ten research avenues for further exploration.\u0000\u0000\u0000Findings\u0000In this study, three research questions discuss the role of environmental sustainability with Industry 4.0. The author predicted ten clusters treated as recent trends on which more insight is required from future researchers. The authors provided year-wise analysis, top authors, top countries, top sources and network analysis related to the topic. Finally, the study provided industrialization’s effect on environmental sustainability and the future aspect of automation.\u0000\u0000\u0000Research limitations/implications\u0000The reliability of the current study may be compromised, notwithstanding the size of the sample used. Poor retrieval of the literature corpus can be attributed to the limitations imposed by the search words, synonyms, string construction and variety of search engines used, as well as to the accurate exclusion of results for which the search string is insufficient.\u0000\u0000\u0000Originality/value\u0000This research is the first-ever study in which a natural language processing technique is implemented to predict future research areas based on the keywords–document relationship.\u0000","PeriodicalId":48601,"journal":{"name":"International Journal of Lean Six Sigma","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-05-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47551237","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-05-12DOI: 10.1108/ijlss-02-2023-0020
Olivia McDermott, Kevin ODwyer, J. Noonan, Anna Trubetskaya, A. Rosa
Purpose This study aims to improve a construction company's overall project delivery by utilising lean six sigma (LSS) methods combined with building information modelling (BIM) to design, modularise and manufacture various building elements in a controlled factory environment off-site. Design/methodology/approach A case study in a construction company utilised lean six sigma (LSS) methodology and BIM to identify non-value add waste in the construction process and improve sustainability. Findings An Irish-based construction company manufacturing modular pipe racks for the pharmaceutical industry utilised LSS to optimise and standardise their off-site manufacturing (OSM) partners process and leverage BIM to design skids which could be manufactured offsite and transported easily with minimal on-site installation and rework required. Productivity was improved, waste was reduced, less energy was consumed, defects were reduced and the project schedule for completion was reduced. Research limitations/implications The case study was carried out on one construction company and one construction product type. Further case studies would ensure more generalisability. However, the implementation was tested on a modular construction company, and the methods used indicate that the generic framework could be applied and customized to any offsite company. Originality/value This is one of the few studies on implementing offsite manufacturing (OSM) utilising LSS and BIM in an Irish construction company. The detailed quantitative benefits and cost savings calculations presented as well as the use of the LSM methods and BIM in designing an OSM process can be leveraged by other construction organisations to understand the benefits of OSM. This study can help demonstrate how LSS and BIM can aid the construction industry to be more environmentally friendly.
{"title":"The development of a lean six sigma and BIM framework for enhancing off-site manufacturing","authors":"Olivia McDermott, Kevin ODwyer, J. Noonan, Anna Trubetskaya, A. Rosa","doi":"10.1108/ijlss-02-2023-0020","DOIUrl":"https://doi.org/10.1108/ijlss-02-2023-0020","url":null,"abstract":"\u0000Purpose\u0000This study aims to improve a construction company's overall project delivery by utilising lean six sigma (LSS) methods combined with building information modelling (BIM) to design, modularise and manufacture various building elements in a controlled factory environment off-site.\u0000\u0000\u0000Design/methodology/approach\u0000A case study in a construction company utilised lean six sigma (LSS) methodology and BIM to identify non-value add waste in the construction process and improve sustainability.\u0000\u0000\u0000Findings\u0000An Irish-based construction company manufacturing modular pipe racks for the pharmaceutical industry utilised LSS to optimise and standardise their off-site manufacturing (OSM) partners process and leverage BIM to design skids which could be manufactured offsite and transported easily with minimal on-site installation and rework required. Productivity was improved, waste was reduced, less energy was consumed, defects were reduced and the project schedule for completion was reduced.\u0000\u0000\u0000Research limitations/implications\u0000The case study was carried out on one construction company and one construction product type. Further case studies would ensure more generalisability. However, the implementation was tested on a modular construction company, and the methods used indicate that the generic framework could be applied and customized to any offsite company.\u0000\u0000\u0000Originality/value\u0000This is one of the few studies on implementing offsite manufacturing (OSM) utilising LSS and BIM in an Irish construction company. The detailed quantitative benefits and cost savings calculations presented as well as the use of the LSM methods and BIM in designing an OSM process can be leveraged by other construction organisations to understand the benefits of OSM. This study can help demonstrate how LSS and BIM can aid the construction industry to be more environmentally friendly.\u0000","PeriodicalId":48601,"journal":{"name":"International Journal of Lean Six Sigma","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46685085","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-05-11DOI: 10.1108/ijlss-11-2021-0203
L. Jum’a, Ziad Alkalha, Karam Al Mandil, Maher Alaraj
Purpose Organizations have released the importance of lean manufacturing practices (LMPs) and total quality management (TQM) in enhancing competitiveness. However, the implementation of LMPs and TQM becomes more complex when discerning the environmental sustainability position. The complexity stems from the fact that LMPs and TQM are more intricate because of cultural differences. Thus, this study aims to tackle the aforementioned phenomenon by investigating the impact of LMPs and TQM on environmental sustainability moderated by quality culture. Design/methodology/approach A survey was distributed among small and medium enterprises (SMEs) in Jordan; thus, 315 valid responses were received. Partial least square structural equation modelling was used to analyze the data and test hypotheses. Findings The findings showed that environmental sustainability was significantly impacted by all the LMP practices except Kanban and all the TQM practices except statistical process control. Moreover, quality culture significantly and negatively moderated the relationship between TQM and environmental sustainability. However, the influence of LMPs on environmental sustainability was not significantly moderated by quality culture. Practical implications This study has implications for policymakers in SMEs, supply chain managers and academics regarding the importance of LMPs and TQM systems for implementing environmental sustainability and the role of quality culture. Social implications This study provides guidelines for decision-makers on the pathways that enable them to sustain the environment to safeguard the natural ecosystem and natural resources for upcoming generations. Originality/value The originality of this study stems from the alignment of LMPs and TQM in enhancing environmental sustainability, taking into consideration the role of quality culture in SMEs, where previous studies failed short to investigate this phenomenon.
{"title":"Exploring the influence of lean manufacturing and total quality management practices on environmental sustainability: the moderating role of quality culture","authors":"L. Jum’a, Ziad Alkalha, Karam Al Mandil, Maher Alaraj","doi":"10.1108/ijlss-11-2021-0203","DOIUrl":"https://doi.org/10.1108/ijlss-11-2021-0203","url":null,"abstract":"\u0000Purpose\u0000Organizations have released the importance of lean manufacturing practices (LMPs) and total quality management (TQM) in enhancing competitiveness. However, the implementation of LMPs and TQM becomes more complex when discerning the environmental sustainability position. The complexity stems from the fact that LMPs and TQM are more intricate because of cultural differences. Thus, this study aims to tackle the aforementioned phenomenon by investigating the impact of LMPs and TQM on environmental sustainability moderated by quality culture.\u0000\u0000\u0000Design/methodology/approach\u0000A survey was distributed among small and medium enterprises (SMEs) in Jordan; thus, 315 valid responses were received. Partial least square structural equation modelling was used to analyze the data and test hypotheses.\u0000\u0000\u0000Findings\u0000The findings showed that environmental sustainability was significantly impacted by all the LMP practices except Kanban and all the TQM practices except statistical process control. Moreover, quality culture significantly and negatively moderated the relationship between TQM and environmental sustainability. However, the influence of LMPs on environmental sustainability was not significantly moderated by quality culture.\u0000\u0000\u0000Practical implications\u0000This study has implications for policymakers in SMEs, supply chain managers and academics regarding the importance of LMPs and TQM systems for implementing environmental sustainability and the role of quality culture.\u0000\u0000\u0000Social implications\u0000This study provides guidelines for decision-makers on the pathways that enable them to sustain the environment to safeguard the natural ecosystem and natural resources for upcoming generations.\u0000\u0000\u0000Originality/value\u0000The originality of this study stems from the alignment of LMPs and TQM in enhancing environmental sustainability, taking into consideration the role of quality culture in SMEs, where previous studies failed short to investigate this phenomenon.\u0000","PeriodicalId":48601,"journal":{"name":"International Journal of Lean Six Sigma","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-05-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45000095","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-04-25DOI: 10.1108/ijlss-05-2022-0100
Karol Moszyk, M. Deja
Purpose The purpose of this paper is to investigate ways to reduce the average amount of exceeded guaranteed service time for external trucks at Deepwater Container Terminal Gdańsk Sp z o.o. (DCT Gdańsk) via dosing the gate activities, in particular IN-Gate entry process, of trucks carrying import/export/transit containers. Design/methodology/approach A Six Sigma methodology with the define, measure, analyze, improve, and Control (DMAIC) methods along with the SIPOC chart, cause and effect diagram, scatterplot, benchmark and brainstorming and finally multi-voting tool are used as analyses tools in this research. Findings DCT Gdańsk reorganized and modernized the gate operations. Gate reorganization and modernization include streaming line traffic at the gates, external parking lot optimization, implementation of dedicated supporting software and installation of dedicated CCTV cameras to provide 24 h live view. During gates development, the external truck service times data were collected and analysed. The obtained materials concerned the measurement of the average truck turnaround time before and after the implementation of the improvements. Originality/value The proposed approach of reducing the average amount of exceeded guaranteed service time of external trucks at the container terminal is unique and relatively cheap mainly due to organizational changes with some widely available low-cost investments and can be applied on a different scale to other container terminals or to transport and logistics companies.
本文的目的是通过对装载进/出口/中转集装箱的卡车的闸门活动(特别是in - gate入口过程)进行定量，研究如何减少深水集装箱码头Gdańsk Sp z o.o (DCT Gdańsk)外部卡车超过保证服务时间的平均数量。设计/方法/方法采用六西格玛方法，采用定义、测量、分析、改进和控制(DMAIC)方法，并采用SIPOC图、因果图、散点图、基准和头脑风暴，最后采用多重投票工具作为分析工具。发现sdct Gdańsk重新组织并现代化了登机口操作。门户重组和现代化包括门户的流线交通，外部停车场优化，实施专用配套软件和安装专用闭路电视摄像机，以提供24小时实时视图。在闸门开发过程中，收集和分析了外部卡车服务时间数据。获得的材料涉及到改进实施前后平均卡车周转时间的测量。原创性/价值提出的减少集装箱码头外部卡车超过保证服务时间的平均数量的方法是独特的，相对便宜，主要是由于组织变革和一些广泛可用的低成本投资，可以以不同的规模应用于其他集装箱码头或运输和物流公司。
{"title":"Reduction of exceeding the guaranteed service time for external trucks at the DCT Gdańsk container terminal using a six sigma framework","authors":"Karol Moszyk, M. Deja","doi":"10.1108/ijlss-05-2022-0100","DOIUrl":"https://doi.org/10.1108/ijlss-05-2022-0100","url":null,"abstract":"\u0000Purpose\u0000The purpose of this paper is to investigate ways to reduce the average amount of exceeded guaranteed service time for external trucks at Deepwater Container Terminal Gdańsk Sp z o.o. (DCT Gdańsk) via dosing the gate activities, in particular IN-Gate entry process, of trucks carrying import/export/transit containers.\u0000\u0000\u0000Design/methodology/approach\u0000A Six Sigma methodology with the define, measure, analyze, improve, and Control (DMAIC) methods along with the SIPOC chart, cause and effect diagram, scatterplot, benchmark and brainstorming and finally multi-voting tool are used as analyses tools in this research.\u0000\u0000\u0000Findings\u0000DCT Gdańsk reorganized and modernized the gate operations. Gate reorganization and modernization include streaming line traffic at the gates, external parking lot optimization, implementation of dedicated supporting software and installation of dedicated CCTV cameras to provide 24 h live view. During gates development, the external truck service times data were collected and analysed. The obtained materials concerned the measurement of the average truck turnaround time before and after the implementation of the improvements.\u0000\u0000\u0000Originality/value\u0000The proposed approach of reducing the average amount of exceeded guaranteed service time of external trucks at the container terminal is unique and relatively cheap mainly due to organizational changes with some widely available low-cost investments and can be applied on a different scale to other container terminals or to transport and logistics companies.\u0000","PeriodicalId":48601,"journal":{"name":"International Journal of Lean Six Sigma","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44583136","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-04-25DOI: 10.1108/ijlss-10-2022-0218
Purushothaman Mahesh Babu, Jeff Seadon, D. Moore
Purpose The purpose of this paper is to highlight the prominent cognitive biases that influence Lean practices in organisations that have a multi-cultural work environment which will aid the organisational managers and academics in enhancing the understanding of the human thought process and mitigate them suitably. Design/methodology/approach A multiple case study was conducted in organisations that were previously committed to Lean practices and had a multi-cultural work environment. This research was conducted on five companies based on 99 in-depth semi-structured interviews and seven process observations that sought to establish the system-wide cognitive biases present in a multi-cultural Lean environment. Findings The novel findings indicate that nine new biases influence Lean implementation and practices in a multi-cultural environment. This study also found strong connectivity between Lean practices and 45 previously identified biases that could affect positively or negatively the lean methodologies and their implementation. Biases were resilient enough that their influence on Lean in multi-cultural workplaces, even with transient populations, did not demonstrate cultural differentiation. Research limitations/implications Like any qualitative research, constructivism and narrative analyses are subjected to understanding based on knowledge gained on the subject, and data may have been interpreted differently. Constructivist co-recreation of process scenarios based result limitations is therefore acknowledged. The interactive participation in exploring the knowledge sought after and interaction that could have a probable influence on the participant need to be acknowledged. However, the research design, multiple methods of data collection, generalisation based on data collection and analysis methods limit the effects of these and findings are reliable to a greater extent. Practical implications The results can provide an enhanced understanding of biases and insights into a new managerial approach to take remedial steps on biases’ influence on Lean practices that can result in improved productivity and well-being from a business process perspective. Understanding and mitigating the prominent biases can aid Lean manufacturing processes and support decision makers and line managers in improving lean methodologies’ effectiveness and productivity. The biases can be negated and used to implement decisions with ease. The influence of biases and the model could be used as a basis to counter implementation barriers. Originality/value To the best of the authors’ knowledge, this is the first study that connects the cognitive perspectives of Lean business processes in a multi-cultural environment to identify the cognitive biases that influence Lean practices in organisations that were previously committed to Lean practices. The novel findings indicate that nine new biases and 45 previously identified biases influence Lean implementation and pr
{"title":"Cognitive biases that influence Lean implementation and practices in a multicultural environment","authors":"Purushothaman Mahesh Babu, Jeff Seadon, D. Moore","doi":"10.1108/ijlss-10-2022-0218","DOIUrl":"https://doi.org/10.1108/ijlss-10-2022-0218","url":null,"abstract":"\u0000Purpose\u0000The purpose of this paper is to highlight the prominent cognitive biases that influence Lean practices in organisations that have a multi-cultural work environment which will aid the organisational managers and academics in enhancing the understanding of the human thought process and mitigate them suitably.\u0000\u0000\u0000Design/methodology/approach\u0000A multiple case study was conducted in organisations that were previously committed to Lean practices and had a multi-cultural work environment. This research was conducted on five companies based on 99 in-depth semi-structured interviews and seven process observations that sought to establish the system-wide cognitive biases present in a multi-cultural Lean environment.\u0000\u0000\u0000Findings\u0000The novel findings indicate that nine new biases influence Lean implementation and practices in a multi-cultural environment. This study also found strong connectivity between Lean practices and 45 previously identified biases that could affect positively or negatively the lean methodologies and their implementation. Biases were resilient enough that their influence on Lean in multi-cultural workplaces, even with transient populations, did not demonstrate cultural differentiation.\u0000\u0000\u0000Research limitations/implications\u0000Like any qualitative research, constructivism and narrative analyses are subjected to understanding based on knowledge gained on the subject, and data may have been interpreted differently. Constructivist co-recreation of process scenarios based result limitations is therefore acknowledged. The interactive participation in exploring the knowledge sought after and interaction that could have a probable influence on the participant need to be acknowledged. However, the research design, multiple methods of data collection, generalisation based on data collection and analysis methods limit the effects of these and findings are reliable to a greater extent.\u0000\u0000\u0000Practical implications\u0000The results can provide an enhanced understanding of biases and insights into a new managerial approach to take remedial steps on biases’ influence on Lean practices that can result in improved productivity and well-being from a business process perspective. Understanding and mitigating the prominent biases can aid Lean manufacturing processes and support decision makers and line managers in improving lean methodologies’ effectiveness and productivity. The biases can be negated and used to implement decisions with ease. The influence of biases and the model could be used as a basis to counter implementation barriers.\u0000\u0000\u0000Originality/value\u0000To the best of the authors’ knowledge, this is the first study that connects the cognitive perspectives of Lean business processes in a multi-cultural environment to identify the cognitive biases that influence Lean practices in organisations that were previously committed to Lean practices. The novel findings indicate that nine new biases and 45 previously identified biases influence Lean implementation and pr","PeriodicalId":48601,"journal":{"name":"International Journal of Lean Six Sigma","volume":null,"pages":null},"PeriodicalIF":4.0,"publicationDate":"2023-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44803132","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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