Integration of Lean practices and Industry 4.0 technologies: smart manufacturing for next-generation enterprises

Shahin, Mohammad; Chen, F. Frank; Bouzary, Hamed; Krishnaiyer, Krishnan

doi:10.1007/s00170-020-05124-0

Cited by 180 publications

(96 citation statements)

References 47 publications

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“…LSS is the fusion of Lean Manufacturing, also known as Lean Thinking at the strategic level, an approach which concentrates on banishing the wastes to establish value proposition in the system, and the Six Sigma methodology to reduce variation to establish robust technology (Antony et al , 2016a; Bhat et al , 2014). In fact, Lean Thinking is recognized as one of the catalysts in I4.0 deployment to provide circular economy and sustainability (Erro-garcés, 2020; Shahin et al , 2020). Lean Thinking concentrates on removing DOWNTIME (Defects, Over-production, Waiting, Non-utilization of Talents, Transportation, Inventory, Motion, Extra-processing), i.e.…”

Section: Introductionmentioning

confidence: 99%

Simulation-based lean six sigma for Industry 4.0: an action research in the process industry

Bhat

Bhat²,

Gijo

2020

IJQRM

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PurposeThe primary aim of this article is to ascertain the modalities of leveraging Lean Six Sigma (LSS) for Industry 4.0 (I4.0) with special reference to the process industries. Moreover, it intends to determine the applicability of simulation-based LSS in the automation of the mineral water industry, with special emphasis on the robust design of the control system to improve productivity and performance.Design/methodology/approachThis study adopts the action research methodology, which is exploratory in nature along with the DMAIC (define-measure-analyze-improve-control) approach to systematically unearth the root causes and to develop robust solutions. The MATLAB simulation software and Minitab statistical software are effectively utilized to draw the inferences.FindingsThe root causes of critical to quality characteristic (CTQ) and variation in purity level of water are addressed through the simulation-based LSS approach. All the process parameters and noise parameters of the reverse osmosis (RO) process are optimized to reduce the errors and to improve the purity of the water. The project shows substantial improvement in the sigma rating from 1.14 to 3.88 due to data-based analysis and actions in the process. Eventually, this assists the management to realize an annual saving of 20% of its production and overhead costs. This study indicates that LSS can be applicable even in the advent of I4.0 by reinforcing the existing approach and embracing data analysis through simulation.Research limitations/implicationsThe limitation of this research is that the inference is drawn based on a single case study confined to process industry automation. Having said that, the methodology deployed, scientific information related to optimization, and technical base established can be generalized.Originality/valueThis article is the first of its kind in establishing the integration of simulation, LSS, and I4.0 with special reference to automation in the process industry. It also delineates the case study in a phase-wise manner to explore the applicability and relevance of LSS with I4.0. The study is archetype in enabling LSS to a new era, and can act as a benchmark document for academicians, researchers, and practitioners for further research and development.

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Section: Introductionmentioning

confidence: 99%

Simulation-based lean six sigma for Industry 4.0: an action research in the process industry

Bhat

Bhat²,

Gijo

2020

IJQRM

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“…Cloud Computing (CC) is implemented in dashboard-type monitoring of the process, enabling managers to make effective decisions [26]. CC along with RFID is used to grasp the real-time production records of production operators and the production equipment's for a labour-intensive production company [27].…”

Section: Industry 40 Tools Supporting Lean Manufacturingmentioning

confidence: 99%

Industry 4.0 Application in Lean Manufacturing – A Systematic Review

Saad¹,

Bhovar²,

Bahadori³

et al. 2021

Advances in Transdisciplinary Engineering

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For several years Lean manufacturing has been adopted by industries in improving the operational performance of the firm. However, Lean manufacturing is associated with fixed production sequence and slow responsiveness, which limits its capability of meeting the constantly changing customer demand, product variability & customisation. This can inhibit its adaptability in the digital era. Meanwhile, Industry 4.0 technologies support the mass production of highly customisable products by being modular and flexible. Although Industry 4.0 technologies can meet the demands of the digital era, they are considered as a solution provider with little scope for organisational process improvement. Hence, an integration of both approaches will lead to a competitive advantage in the digital era. This paper aims to explore and evaluate the work done by researchers in identifying the link between lean manufacturing and Industry 4.0 technologies, through a systematic literature review to understand if lean manufacturing and Industry 4.0 technology can be integrated effectively.

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“…The question posed by Mrugalska et al [164] has been addressed by many authors, both theoretically and analyzing use cases across many countries: "Can Lean and Industry 4.0 coexist and support each other, and if so, how?" There are four main lines of thought when answering this question: (1) Lean techniques and Industry 4.0 technologies interact in a positive way, and there are many cases to illustrate this [8,9,165,166]; (2) Lean facilitates the change towards Industry 4.0 [167,168];…”

Section: The Interaction Between Lean Production and Industry 40mentioning

confidence: 99%

Lean Manual Assembly 4.0: A Systematic Review

2020

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In a demand context of mass customization, shifting towards the mass personalization of products, assembly operations face the trade-off between highly productive automated systems and flexible manual operators. Novel digital technologies—conceptualized as Industry 4.0—suggest the possibility of simultaneously achieving superior productivity and flexibility. This article aims to address how Industry 4.0 technologies could improve the productivity, flexibility and quality of assembly operations. A systematic literature review was carried out, including 234 peer-reviewed articles from 2010–2020. As a result, the analysis was structured addressing four sets of research questions regarding (1) assembly for mass customization; (2) Industry 4.0 and performance evaluation; (3) Lean production as a starting point for smart factories, and (4) the implications of Industry 4.0 for people in assembly operations. It was found that mass customization brings great complexity that needs to be addressed at different levels from a holistic point of view; that Industry 4.0 offers powerful tools to achieve superior productivity and flexibility in assembly; that Lean is a great starting point for implementing such changes; and that people need to be considered central to Assembly 4.0. Developing methodologies for implementing Industry 4.0 to achieve specific business goals remains an open research topic.

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Integration of Lean practices and Industry 4.0 technologies: smart manufacturing for next-generation enterprises

Cited by 180 publications

References 47 publications

Simulation-based lean six sigma for Industry 4.0: an action research in the process industry

Simulation-based lean six sigma for Industry 4.0: an action research in the process industry

Industry 4.0 Application in Lean Manufacturing – A Systematic Review

Lean Manual Assembly 4.0: A Systematic Review

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