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Article
Publication date: 5 July 2013

S. Vinodh, M. Somanaathan and K.R. Arvind

This paper aims to explore the practical feasibility of deploying value stream mapping (VSM) for enabling lean manufacturing.

2262

Abstract

Purpose

This paper aims to explore the practical feasibility of deploying value stream mapping (VSM) for enabling lean manufacturing.

Design/methodology/approach

The literature on lean manufacturing and VSM has been reviewed. VSM has been selected as a technique for solving the problem existing in the case organization. The current state map has been developed after making necessary observations and calculations. Then various improvement proposals have been identified and the future state map has been developed. The simulation approach has been used for validating performance improvements. The practicality of the approach has been validated.

Findings

Two kinds of validation are being conducted in the case organization using questionnaire based approach. In the first stage, the practical receptivity of deploying the proposals has been gathered from the executives. In the second stage, statistical validation has been performed.

Research limitations/implications

VSM has been applied for solving the problem in the case organisation. But the organisation has implemented world class strategies such as ISO quality management system and total quality management. Hence, the experiences gained by the conduct of this implementation study are feasible and deployable in similar organisations.

Practical implications

In order to acquire lean characteristics, modern organisations are focussed on the implementation of various lean tools/techniques. The results of the implementation study indicated significant improvement in lean characteristics.

Originality/value

The implementation study reported in this article is an original contribution of the authors which has been conducted in a typical industrial scenario. By the virtue of its research background and practical compatibility, the implementation study is considered to be highly valuable.

Details

Journal of Engineering, Design and Technology, vol. 11 no. 2
Type: Research Article
ISSN: 1726-0531

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Article
Publication date: 12 September 2010

S. Vinodh, K.R. Arvind and M. Somanaathan

The purpose of this paper is to apply value stream mapping (VSM) for enabling leanness in an Indian camshaft manufacturing organisation.

4181

Abstract

Purpose

The purpose of this paper is to apply value stream mapping (VSM) for enabling leanness in an Indian camshaft manufacturing organisation.

Design/methodology/approach

Literature on lean manufacturing and VSM has been performed. A suitable organisation has been identified for conducting the case study. The current state map has been developed after making necessary observations and calculations. Then various improvement proposals have been identified and the future state map has been developed.

Findings

The industrial impact as a result of implementing the proposals has been determined. The improvement in leanness parameters has been found.

Research limitations/implications

The implementation study has been conducted in only one organisation. But the organisation has implemented world‐class strategies such as ISO quality management system. Hence, the experiences gained by the conduct of this implementation study are feasible and deployable in similar organisations.

Practical implications

In order to acquire lean characteristics, modern organisations are focussed on the test implementation of various lean tools. The results of the implementation study indicated significant improvement in lean characteristics.

Originality/value

The implementation study reported in this paper is an original contribution of the authors, which has been conducted in a typical Indian industrial scenario. By the virtue of its research background and practical compatibility, the implementation study is considered to be highly valuable.

Details

Journal of Manufacturing Technology Management, vol. 21 no. 7
Type: Research Article
ISSN: 1741-038X

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Article
Publication date: 3 July 2017

Sajan M.P., Shalij P.R., Ramesh A. and Biju Augustine P.

The relevance of small and medium enterprises (SMEs) in contributing to the economy and social development is increasingly felt in the current business environment. Focusing on…

3104

Abstract

Purpose

The relevance of small and medium enterprises (SMEs) in contributing to the economy and social development is increasingly felt in the current business environment. Focusing on sustainable development, SMEs have also implemented many acting strategies of large-scale enterprises such as lean and green practices. The purpose of this paper is to investigate the linkage between lean manufacturing practices (LMPs) in SMEs and their sustainability performances. Further, this study explores the relationship between the triple bottom line sustainability performances.

Design/methodology/approach

The study is based on a survey conducted and data collected from 252 manufacturing SMEs in India. The hypothesized relationships are then analyzed with structural equation modeling.

Findings

The outcome of the analysis shows that LMPs are positively associated with various sustainability performances categorized as economic, environmental, and social performances. Further, this study shows that environmental sustainability is correlated with economic and social sustainability performances.

Research limitations/implications

The study conducted was limited to a particular state in India. Moreover, the study uses the data from a cross-sectional survey from single respondents.

Practical implications

The findings of the study become an added advantage for the managers to convince their various stakeholders for implementing LMPs in SMEs.

Originality/value

The research findings provide theoretical and practical insights to derive the importance of LMPs in maximizing sustainability performances. It gives an enhanced perspective of the importance of LMPs on the sustainability performance of SMEs.

Details

Journal of Manufacturing Technology Management, vol. 28 no. 6
Type: Research Article
ISSN: 1741-038X

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Article
Publication date: 6 March 2024

Gaurav Kumar Badhotiya, Anand Gurumurthy, Yogesh Marawar and Gunjan Soni

Lean manufacturing (LM) concepts have been widely adopted in diverse industrial sectors. However, no literature review focusing on case studies describing LM implementation is…

537

Abstract

Purpose

Lean manufacturing (LM) concepts have been widely adopted in diverse industrial sectors. However, no literature review focusing on case studies describing LM implementation is available. Case studies represent the actual implementation and provide secondary data for further analysis. This study aims to review the same to understand the pathways of LM implementation. In addition, it aims to analyse other related review questions, such as how implementing LM impacts manufacturing capabilities and the maturity level of manufacturing organisations that implemented LM, to name a few.

Design/methodology/approach

A literature review of case studies that discuss the implementation of LM during the last decade (from 2010 to 2020) is carried out. These studies were synthesised, and content analyses were performed to reveal critical insights.

Findings

The implementation pattern of LM significantly varies across manufacturing organisations. The findings show simultaneous improvement in manufacturing capabilities. Towards the end of the last decade, organisations implemented LM with radio frequency identification, e-kanban, simulation, etc.

Originality/value

Reviewing the case studies documenting LM implementation to comprehend the various nuances is a novel attempt. Furthermore, potential future research directions are identified for advancing the research in the domain of LM.

Details

Journal of Manufacturing Technology Management, vol. 35 no. 4
Type: Research Article
ISSN: 1741-038X

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Article
Publication date: 10 January 2020

Ahmed Zainul Abideen and Fazeeda Binti Mohamad

The purpose of this study is to apply value stream mapping (VSM) in Malaysian pharmaceutical production warehouse. A current and future state value stream map from the raw…

3419

Abstract

Purpose

The purpose of this study is to apply value stream mapping (VSM) in Malaysian pharmaceutical production warehouse. A current and future state value stream map from the raw material receiving end to the production unit was developed to find out waste and unwanted lead time. It was very much essential to cut down the supply chain lead time at the initial phase as the raw material unloading, sorting, temporary storage and dispatch to production were seen contributing to a huge lead time build-up.

Design/methodology/approach

The study was initiated with the selection of a product family, construction of the current state map, identification of various wastes and the development of future state map.

Findings

The expected outcomes of the study include the quantification of wastes, improvement in value-added percentage and lead time reduction.

Research limitations/implications

The study was carried out in a single pharmaceutical company. The results of the study are deployable and can be functional in similar production organizations. Contrary to common VSMs that capture core production processes, this study provides strong insights that shall help design lean supply chains, especially in the pharmaceutical domain. This paper has also addressed the viability of the lean in the pharmaceutical warehouse and the reduction in lead time to improve demand forecasting, marketing and sales.

Practical implications

The results of this study have indicated that a significant reduction in pharmaceutical warehouse supply chain lead time is possible as a result of the implementation of VSM from the supply chain’s perspective.

Social implications

The insights from this study help in understanding the pharmaceutical supply chain risks and their outcomes.

Originality/value

The paper reports a real-time study conducted in a warehouse of a pharmaceutical organization. Hence, the contributions are original.

Details

International Journal of Pharmaceutical and Healthcare Marketing, vol. 14 no. 1
Type: Research Article
ISSN: 1750-6123

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Article
Publication date: 13 May 2024

Anand S. Patel and Kaushik M. Patel

India liberalized its economy in 1991, which resulted in intense global competition, quality-conscious and demanding customers. Additionally, significant technological…

239

Abstract

Purpose

India liberalized its economy in 1991, which resulted in intense global competition, quality-conscious and demanding customers. Additionally, significant technological advancements lead to enhancements in products and processes. These forced Indian organizations to adopt innovative business strategies in the past 30 years. Meanwhile, the Lean Six Sigma methodology has significantly grown with vast applicability during the past 30 years. Thus, the purpose of this study is to develop the learning on Lean Six Sigma methodology in the Indian context through investigation of literature.

Design/methodology/approach

A three-stage systematic literature review approach was adopted to investigate the literature during the present study. In total, 187 articles published in 62 journals/conference proceedings from 2005 to 2022 (18 years) were shortlisted. The first part of the article summarizes the significant milestones towards the quality journey in the Indian context, along with the evolution of the Lean Six Sigma methodology. The second part examines the shortlisted papers on Lean Six Sigma frameworks, their applicability in industrial sectors, performance metrics, outcomes realized, publication trends, authorship patterns and leading researchers from the Indian perspective.

Findings

Lean Six Sigma has emerged as a highly acclaimed and structured business improvement strategy worldwide. The Indian economy has seen remarkable growth in the past decade and is one of the fastest-growing economies in the 21st century. Lean Six Sigma implementation in India has significantly increased from 2014 onward. The study revealed that researchers have proposed several different frameworks for Lean Six Sigma implementation, the majority of which are conceptual. Furthermore, the balanced applicability of Lean Six Sigma in manufacturing and service sectors was observed with the highest implementation in the health-care sector. Additionally, the widely adopted tools, techniques along with performance metrics exploring case studies were reported along with a summary of eminent and leading researchers in the Indian context.

Research limitations/implications

This study is confined to reviewed papers as per the research criteria with a significant focus on the Indian context and might have missed some papers due to the adopted papers selection strategy.

Originality/value

The present study is one of the initial attempts to investigate the literature published on Lean Six Sigma in the Indian context, including perspective on the Indian quality movement. Therefore, the present study will provide an understanding of Lean Six Sigma methodology in the Indian context to graduating students in engineering and management and entry-level executives. The analysis and findings on Lean Six Sigma frameworks, research approach, publications details, etc., will be helpful to potential research scholars and academia. Additionally, analysis of case studies on Lean Six Sigma implementation by Indian industries will assist the managers and professionals in decision making.

Details

International Journal of Lean Six Sigma, vol. 15 no. 7
Type: Research Article
ISSN: 2040-4166

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Article
Publication date: 27 December 2022

Anand S. Patel and Kaushik M. Patel

Evidence indicates that the Indian economy has grown enormously in recent years. and Lean Six Sigma (LSS) has evolved globally as a structured business improvement strategy with…

275

Abstract

Purpose

Evidence indicates that the Indian economy has grown enormously in recent years. and Lean Six Sigma (LSS) has evolved globally as a structured business improvement strategy with diverse applicability in the last fifteen years. Therefore, this paper aims to investigate the status of LSS implementation in Indian industries using a survey research technique.

Design/methodology/approach

A survey questionnaire was devised from the literature, containing 25 questions to assess respondents’ awareness of the LSS methodology and gain insights on aspects associated with LSS adoption in Indian industries. The survey questionnaire was validated and was conducted using randomly sampled respondents from the Confederation of Indian Industries membership database. The collected data were statistically analyzed using IBM SPSS and MS Excel.

Findings

The findings attest that adopting LSS is not so encouraging and extremely poor in small- and medium-scale Indian industries. ISO 9001 emerged as a prominent quality improvement program. It is learnt that consultants play a pivotal role in bringing awareness and skills building while implementing LSS. Results endorse top management commitment and involvement, and resistance to change as leading success factors and challenges, respectively. Further, it is revealed that respondents were highly satisfied after the adoption of LSS.

Research limitations/implications

The findings of this study were derived from 183 responses and should be generalized cautiously.

Originality/value

This paper provides valuable insights on the present status covering the issues related to L:SS implementation in India. These results can motivate the managers of Indian industries for wide adoption of the LSS methodology. In addition, the findings of the paper may assist the researchers providing direction to carry out further research in LSS in the Indian context.

Details

International Journal of Lean Six Sigma, vol. 14 no. 4
Type: Research Article
ISSN: 2040-4166

Keywords

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Article
Publication date: 7 December 2020

Hichem Aouag, Mohyiddine Soltani and Mohamed Djamel Mouss

This paper aims to investigate an integrated approach that aims at enhancing the application process of value stream mapping (VSM) method. It also proposes an extended VSM called…

386

Abstract

Purpose

This paper aims to investigate an integrated approach that aims at enhancing the application process of value stream mapping (VSM) method. It also proposes an extended VSM called Economic and Environmental VSM(E-EVSM). The proposed approach highlights the improvement of economic and environmental performances.

Design/methodology/approach

The proposed approach has studied the integration of VSM, fuzzy decision-making trial and evaluation laboratory (DEMATEL) and fuzzy quality function deployment (QFD) to improve the economic and environmental performances of manufacturing processes. The VSM method is used for data collection and manufacturing process assessment, whereas fuzzy DEMATEL is used to analyse the current state map. Finally, fuzzy QFD is used to organize the improvement phase of VSM method.

Findings

The clear findings of this research prove the effectiveness of VSM method on the environmental and economic performances of manufacturing processes. In addition, the proposed approach will show the advantages of fuzzy DEMATEL and fuzzy QFD approaches in improving the application of the VSM method.

Research limitations/implications

The limitation of this study includes the lack of consideration of other dimensions such as social, technological and managerial. In addition, the proposed approach studied an average set of environmental and economic indicators.

Originality/value

The novelty of the proposed approach is proved by the development of an extended VSM method (E-EVSM). Also, the proposed approach contributes by a new methodology for analysing and improving the current state map of manufacturing processes.

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Article
Publication date: 15 January 2019

Yash Dave and Nagendra Sohani

The core principle of implementing Lean manufacturing is reducing waste through optimum utilization of all resources. In this research paper, the authors have examined the effect…

1454

Abstract

Purpose

The core principle of implementing Lean manufacturing is reducing waste through optimum utilization of all resources. In this research paper, the authors have examined the effect of implementing Lean practices on the overall productivity in central India-based manufacturing industries. The purpose of this research paper is to investigate the relationship between the implementation of Lean practices and overall productivity particularly in central India-based manufacturing industries.

Design/methodology/approach

A model in the integrated form is developed to illustrate how Lean manufacturing practices improve the overall productivity. Based on this model, a survey is performed to validate all hypotheses related to the conceptual model subject to various statistical tests.

Findings

It is established by the findings of this research that industries based in central India should implement the whole concept of Lean manufacturing practices to improve overall productivity. Industries should adopt the concept of Lean manufacturing in totality, not through the island approach.

Originality/value

The value of this research paper is to showcase the possibility for central India-based companies to become world-class industries. For this, an approach in the form of an integrated model has been developed.

Details

International Journal of Lean Six Sigma, vol. 10 no. 2
Type: Research Article
ISSN: 2040-4166

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Article
Publication date: 25 May 2022

Chaochao Liu and Yang Zhang

Value stream mapping (VSM) is a visualization tool to identify and eliminate waste and widely applied in manufacturing, transportation, construction, service and other industries…

385

Abstract

Purpose

Value stream mapping (VSM) is a visualization tool to identify and eliminate waste and widely applied in manufacturing, transportation, construction, service and other industries, especially in the Industrial 4.0 technology era. The purpose of this paper is to review and analyze the VSM literature to identify the advances and hotspots of VSM literature.

Design/methodology/approach

Taking the VSM literature collected from the Web of Science Core Collection database as the research samples, this research used the bibliometric and keyword co-occurrence analysis to analyze the publication trend, research topics and their contents of VSM from concept integration, application sectors and technology expansion.

Findings

With the development of research, the latest research integrates conceptual integration, application departments and technology expansion to develop more complex research designs. It can be integrated with simulation, six sigma, big data, Internet of Things and other technologies to expand the analysis and design ability of VSM, which enhances the adaptability of VSM to various scenarios.

Originality/value

This research contributes to VSM literature by conducting a systematic review based on the citation structure within VSM research and identifies the established and emerging areas of research on VSM.

Details

International Journal of Lean Six Sigma, vol. 14 no. 1
Type: Research Article
ISSN: 2040-4166

Keywords

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