Extending lean frontiers: a kaizen case study in an Italian MTO manufacturing company

Rossini, Matteo; Audino, Francesco; Costa, Federica; Cifone, Fabiana Dafne; Kundu, Kaustav; Staudacher, Alberto Portioli

doi:10.1007/s00170-019-03990-x

Cited by 44 publications

(36 citation statements)

References 39 publications

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“…While every single shop in practice could differ from the stylized model, it captures the job and shop characteristics of MTO companies, i.e. high processing time variability and high arrival rate variability (Rossini et al, 2019). The shop and job characteristics modelled in the simulations are first summarized in Section 3.1.…”

Section: Methodsmentioning

confidence: 99%

The use of labour flexibility for output control in workload controlled flow shops: A simulation analysis

Staudacher¹,

Costa²,

Thürer³

2020

10.5267/j.ijiec

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Workload control theory seeks to align capacity and demand to improve delivery performance. However, workload control researchers mainly focused on input control, which regulates the input of work to the production system, thereby neglecting output control, which uses capacity adjustments to regulate the outflow of the work. Moreover, few existing studies on output control investigate a temporarily increase in capacity. This paper introduces a new search direction for output control which does not require an increase in capacity-labour flexibility. Idle operators can move from their workstation to another, thus temporarily increasing the output of that workstation without extra capacity. Using simulation of a five workstations flow shop line, we highlight the positive performance effect of labour flexibility. However, this comes at the cost of high labour movement. Introducing a load-based constraint on when workers are allowed to move significantly reduces labour movement, while realizing most of the performance improvement observed for unconstrained labour movement. This has important implications for future research and practice.

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Section: Methodsmentioning

confidence: 99%

The use of labour flexibility for output control in workload controlled flow shops: A simulation analysis

Staudacher¹,

Costa²,

Thürer³

2020

10.5267/j.ijiec

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“…of the main experimental factors. While every shop in practice could differ from the stylized model, it captures the job and shop characteristics of MTO companies, i.e., high processing time variability and high arrival rate variability (Rossini et al 2019). We have kept our flow shop relatively small since this allows causal factors to be identified more easily.…”

Section: Simulation Assessmentmentioning

confidence: 99%

Labor flexibility integration in workload control in Industry 4.0 era

Costa

Staudacher

2021

Oper Manag Res

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The paradigm shift toward Industry 4.0 is facilitating human capability, and at the center of the research are the workers—Operator 4.0—and their knowledge. For example, new advances in augmented reality and human–machine interfaces have facilitated the transfer of knowledge, creating an increasing need for labor flexibility. Such flexibility represents a managerial tool for achieving volume and mix flexibility and a strategic means of facing the uncertainty of markets and growing global competition. To cope with these phenomena, which are even more challenging in high-variety, low-volume contexts, production planning and control help companies set reliable due dates and shorten lead times. However, integrating labor flexibility into the most consolidated production planning and control mechanism for a high-variety, low-volume context—workload control—has been quite overlooked, even though the benefits have been largely demonstrated. This paper presents a mathematical model of workload control that integrates labor flexibility into the order review and release phase and simulates the impact on performance. The main results show that worker transfers occur when they are most needed and are minimized compared to when labor flexibility is at a lower level of control—shop-floor level—thus reducing lead time.

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“…Le CI est avant tout une approche basée sur les processus et suppose que l'amélioration des performances peut être atteinte si et seulement si de meilleurs processus sont créés (Darlington et al, 2015). D'après , un projet ou évènement Kaizen s'effectue en quatre phases à savoir la planification qui consiste à définir un planning des besoins en amélioration, le travail préparatoire qui est un travail d'analyse des besoins, l'identification des actions pour la solution et enfin la mise en oeuvre des actions qui est l'évènement Kaizen proprement dit (Rossini, Audino, et al, 2019). La durée maximale d'un projet Kaizen est de 5 jours avec une équipe entièrement dédiée au projet (Rossini, Audino, et al, 2019).…”

Section: Le Continuous Improvementunclassified

“…D'après , un projet ou évènement Kaizen s'effectue en quatre phases à savoir la planification qui consiste à définir un planning des besoins en amélioration, le travail préparatoire qui est un travail d'analyse des besoins, l'identification des actions pour la solution et enfin la mise en oeuvre des actions qui est l'évènement Kaizen proprement dit (Rossini, Audino, et al, 2019). La durée maximale d'un projet Kaizen est de 5 jours avec une équipe entièrement dédiée au projet (Rossini, Audino, et al, 2019). Lyonnet (2010) quant à elle, suggère que le processus d'un CI soit modélisé par la roue de Deming ou approche PDCA : Planifier (Plan), Réaliser (Do), Vérifier (Check) Agir (Act) (Lyonnet, 2010).…”

Section: Le Continuous Improvementunclassified

Les objets connectés pour améliorer la culture de la production épurée : revue de littérature et esquisse de solution applicable aux entreprises manufacturières

Tadja¹,

Bassetto²,

Tollenaere³

et al. 2021

induProd

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Ce travail vise à montrer l'importance des objets connectés pour améliorer la culture de la production épurée. Afin d'atteindre cet objectif, la revue de littérature qui englobe la production épurée, l'industrie 4.0 et le comportement des équipes de travail a été basée sur le processus de revue de littérature adapté de l'Université Concordia (2020) et de Machi (2012). À la fin de ce travail, il a été possible de structurer les pratiques techniques de la production épurée en 5 méthodes et d'identifier 8 principaux groupes technologiques de l'industrie 4.0. Le fruit qui ressort de ce travail est une proposition applicable aux entreprises manufacturières. Celle-ci est le système « lean coach CNV » basé sur les objets connectés dont l'application a le potentiel de promouvoir la culture de la production épurée. En plus de constituer une source d'actualisation de l'enseignement de la production épurée, sur le plan pratique, la proposition contenue dans ce travail est une piste de solution au problème connu de l'échec de mise en oeuvre de la production épurée au sein des entreprises manufacturières. ABSTRACT. This work aims to show importance of Industrial Internet of Things to improve lean manufacturing culture. The literature review that encompasses lean manufacturing, industry 4.0 and teamwork behaviour, is based on Concordia University Library (2020) and Machi (2012) literature review processes. From this work, it has been possible to structure lean manufacturing technical practices into 5 methods and identify 8 main industry 4.0 technological groups. The fruit of this work is a NVC lean coach system based on the integration of industrial internet of thing to seed lean manufacturing culture. Although this system is at proposal stage, it is a potential solution to the known problem of lean manufacturing implementation failure in manufacturing plants. At teaching level, it will contribute to update lean manufacturing courses. MOTS-CLÉS. Production épurée, Objets connectés, Comportement des équipes de travail.

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Extending lean frontiers: a kaizen case study in an Italian MTO manufacturing company

Cited by 44 publications

References 39 publications

The use of labour flexibility for output control in workload controlled flow shops: A simulation analysis

The use of labour flexibility for output control in workload controlled flow shops: A simulation analysis

Labor flexibility integration in workload control in Industry 4.0 era

Les objets connectés pour améliorer la culture de la production épurée : revue de littérature et esquisse de solution applicable aux entreprises manufacturières

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