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Article
Publication date: 20 January 2025

R. Vigneshvaran and S. Vinodh

Organisations are looking for a concept that can solve traditional as well upgraded production problems with current resources and technology, and this can be addressed by…

17

Abstract

Purpose

Organisations are looking for a concept that can solve traditional as well upgraded production problems with current resources and technology, and this can be addressed by integration of lean six sigma (LSS) with Industry 4.0 (I4.0) technologies. This reduces complexity in the manufacturing process through digital technologies. Cyber physical system (CPS) is considered as primary I4.0 technology with which all other technologies are associated to extend. CPS can integrate with other prevailing manufacturing approaches like lean, LSS and so on. LSS, on the other hand, is a team-focussed performance improvement strategy which is widely used by the industries to identify problems, eliminate waste to meet customer requirements. The study aims at analysis of challenges for LSS and CPS integration.

Design/methodology/approach

Integrating LSS and CPS will solve both traditional and modern manufacturing problems. To integrate these technologies, organisational requirements need to be assessed. These requirements are posed as challenges in this study. Their priority weights are analysed, and challenges are prioritised using fuzzy Combinative Distance-based Assessment (CODAS) method. Sensitivity analysis is employed to assess the robustness of the results.

Findings

The result of this study enables top management to integrate LSS and CPS. In this study, 20 challenges were identified, and they are assessed to compute their relative assessment score. Requirement of new tools and methods with 0.6 score ranks first followed by interplay with big data and requirement of new communication protocol. The result highlighted the need for integration of LSS and CPS, proper utilisation of information and communication technologies, and cyber security management as the main impediments that need to be addressed to implement CPS in an LSS environment.

Originality/value

The analysis of challenges of LSS and CPS integration using MCDM tool is the original contribution of the authors.

Details

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

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Article
Publication date: 8 January 2025

Rohit, S. Vinodh and R. Vigneshvaran

This study aims to provide an analysis of cyber-physical system (CPS)-based lean tools. This study focuses on the identification of lean tools for integration with CPS and…

37

Abstract

Purpose

This study aims to provide an analysis of cyber-physical system (CPS)-based lean tools. This study focuses on the identification of lean tools for integration with CPS and analyzes those tools using MCDM (multi-criteria decision-making) approaches.

Design/methodology/approach

There exists a need to integrate lean manufacturing with Industry 4.0 technologies. According to literature analysis, CPS is the first stage to implement Industry 4.0 technologies. Based on the extensive study, six CPS-based lean tools, i.e. CPS-based Jidoka system, CPS-based Kanban, CPS-based Andon support system, CPS-based Just-in-time delivery system, CPS-based poka-yoke cell and CPS-based value stream mapping have been considered; then Grey TOPSIS (Technique for Order Preference by Similarity to Ideal Solution) MCDM technique has been applied to rank those tools. These CPS-based lean tools are ranked based on seven performance measures as recognized by academic and industry experts.

Findings

The top three CPS-based lean tools are CPS-based Kanban 4.0, CPS-based value stream mapping and CPS-based Just-in-time delivery system have been selected based on the above ranking. The study results have been validated using grey-based approach.

Practical implications

Appropriate criteria to evaluate significant lean tools for integration with CPS are identified, which facilitates managers to assess their current tools and technologies that could be integrated with I4.0, and the implementation of CPS-based lean tools would improve organizational performance.

Originality/value

In the emerging Industry 4.0, integration with advanced technologies provides high degrees of optimization. But there exist challenges for industries to integrate CPS with lean tools; hence, this study attempts to identify and analyze CPS-based lean tools. The lean tools are ranked for integration with CPS, the problem is modeled as MCDM problem, and the obtained results are again validated using grey approach. Prioritizing lean tools for integration with CPS is the original contribution of this study.

Details

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

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Article
Publication date: 30 November 2020

Vigneshvaran R and S. Vinodh

To develop a structural model based on Interpretive Structural Modelling (ISM) approach to analyse the barriers to integration of Lean with Industry 4.0.

619

Abstract

Purpose

To develop a structural model based on Interpretive Structural Modelling (ISM) approach to analyse the barriers to integration of Lean with Industry 4.0.

Design/methodology/approach

Integrated lean and I4.0 is essential for optimising customer value, rapid product design and redesign to comply with customer demand on time. Also, manufacturing processes to be made more flexible, intelligent and agile. In this context, integrated lean and Industry 4.0 barriers were identified and an ISM approach is employed to identify hierarchical structure of barriers and analysed.

Findings

The result obtained reflects that barriers “increasing competitive pressure”, “lack of long-term vision”, “lack of management support”, “lack of capital fund” are found to be the important barriers that affect the integration of lean and I4.0.

Research limitations/implications

In the present study, 16 barriers are analysed. In future, additional barriers could be included.

Practical implications

The driving and dependence power of barriers were analysed from ISM model and it provided guidance for practitioners to concentrate on barriers for integrating lean and I4.0.

Originality/value

The idea of developing structural model for analysis of barriers to integration of lean with I4.0 is the original contribution.

Details

The TQM Journal, vol. 33 no. 6
Type: Research Article
ISSN: 1754-2731

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Article
Publication date: 16 May 2023

Raphaella Ferreira Cordeiro, Luciana Paula Reis and June Marques Fernandes

This research aims to evaluate the impact of barriers experienced by Brazilian companies in adopting Industry 4.0 (I4.0).

534

Abstract

Purpose

This research aims to evaluate the impact of barriers experienced by Brazilian companies in adopting Industry 4.0 (I4.0).

Design/methodology/approach

As a methodological approach, the survey method was used, adopting the use of the questionnaire for data collection. From the feedback of 99 companies (with an index of 80%), quantitative analyzes of the data were carried out with the aid of factor analysis and linear regression to validate the proposed structural model.

Findings

The barriers construct does not impact the I4.0 adoption construct. Directly evaluating the effect of the variables that make up the barriers construct in the I4.0 adoption construct, it was observed that three barriers affect effectively the adoption of I4.0: technological infrastructure; financial constraint and lack of understanding of the benefits of I4.0.

Research limitations/implications

As a limitation, the research was conducted only in the Brazilian context, requiring the development of future studies in other countries that can strengthen the findings of this research.

Practical implications

In addition, the results achieved provide relevant insights into public policymakers and business managers, helping them to deeply understand the barriers that impact the adoption of I4.0. This facilitates the propagation of I4.0 concepts in the context of Brazilian companies and in the formulation of public policies adapted to each sector, allowing a more assertive action in the face of the types of barriers experienced by organizations during the adoption of I4.0.

Social implications

The findings can help practitioners and policymakers to understand in detail this new industrial model and the difficulties that prevent its implementation.

Originality/value

From an extensive literature review, no studies were identified that statistically validate which barriers effectively affect the adoption of I4.0. This research is a pioneer in proposing a structural model to analyze the barriers experienced by workers during the adoption of I4.0, exploring Brazilian companies, from different economic sectors and sizes. It is noteworthy that the literature still focuses efforts on manufacturing companies.

Details

The TQM Journal, vol. 36 no. 1
Type: Research Article
ISSN: 1754-2731

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Article
Publication date: 30 May 2024

Alinda Kokkinou, Ton van Kollenburg, Gijs Mathijssen, Emma Vissers and Sem van Doren

To deal with an increasingly competitive environment, organizations are combining continuous improvement (CI) practices with digitalization to accrue their benefits on operational…

127

Abstract

Purpose

To deal with an increasingly competitive environment, organizations are combining continuous improvement (CI) practices with digitalization to accrue their benefits on operational performance and achieve operational excellence. The purpose of this study was to identify the enablers and inhibitors of digitalization as part of CI projects.

Design/methodology/approach

A mixed-methods sequential explanatory research design consisting of an online survey and semi-structured interviews was used to examine how digitalization technologies have been incorporated by organizations in their CI projects.

Findings

Key enablers of digitalization were found to be leadership capabilities, strategic direction, stakeholder involvement, system compatibility, data quality and giving employees room to experiment. Knowledge of digitalization was found to affect all these enablers.

Research limitations/implications

The empirical findings are based on a nonprobability sample of Dutch CI practitioners, limiting their generalizability.

Practical implications

The empirical findings highlight the need for organizations to adopt a structured approach to implementing digitalization as part of their CI projects, starting by ensuring that the necessary knowledge and skills are either present or accessible to the organization.

Originality/value

The empirical findings show that enablers of digitalization in the context of CI are strongly interlinked, and thus require a holistic approach.

Details

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

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Article
Publication date: 10 March 2022

Ravindra Ojha

The purpose of this research paper is to study the digital accelerators in conjunction with lean manufacturing enablers in the technology driven Industry 4.0 (I4.0) and understand…

1011

Abstract

Purpose

The purpose of this research paper is to study the digital accelerators in conjunction with lean manufacturing enablers in the technology driven Industry 4.0 (I4.0) and understand their interrelationship dynamics with a goal to accelerate the pace of manufacturing excellence.

Design/methodology/approach

Literature review coupled with the focus group approach facilitated to cull the key accelerating enablers to lean in I4.0. Thereafter, application of the multi criteria decision making methodology–DEMATEL (Decision Making Trial and Evaluation Laboratory) was carried out for analysis.

Findings

A total of 18 factors from the integration of lean in I4.0 were identified from the focus group approach. The analysis from DEMATEL approach reflected that big data analytics and technology driven talent were the two most important factors in the manufacturing excellence journey. Leadership standard work and continuous improvement culture were the two key cause category factors, while, just in time the critical effect category factor.

Practical implications

Analysis from DEMATEL approach has provided useful insights to industry leaders with the details of the degree of importance and type of influencing factors. It has given them direction in areas of investment to face the challenges of smart factories of tomorrow for sustainability.

Originality/value

Application of DEMATEL approach for analyzing the dynamics of the 18 factors in the integrated lean systems in I4.0 for manufacturing excellence.

Details

The TQM Journal, vol. 35 no. 3
Type: Research Article
ISSN: 1754-2731

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Article
Publication date: 19 April 2023

Sameh M. Saad, Ramin Bahadori, Chandan Bhovar and Hongwei Zhang

This paper aims to analyse the current state of research to identify the link between Lean Manufacturing and Industry 4.0 (I4.0) technologies to map out different research themes…

1007

Abstract

Purpose

This paper aims to analyse the current state of research to identify the link between Lean Manufacturing and Industry 4.0 (I4.0) technologies to map out different research themes, to uncover research gaps and propose key recommendations for future research, including lessons to be learnt from the integration of lean and I4.0.

Design/methodology/approach

A systematic literature review (SLR) is conducted to thematically analyse and synthesise existing literature on Lean Manufacturing–I4.0 integration. The review analysed 60 papers in peer-reviewed journals.

Findings

In total, five main research themes were identified, and a thematic map was created to explore the following: the relationship between Lean Manufacturing and I4.0; Lean Manufacturing and I4.0 implication on performance; Lean Manufacturing and I4.0 framework; Lean Manufacturing and I4.0 integration with other methodologies; and application of I4.0 technologies in Lean Manufacturing. Furthermore, various gaps in the literature were identified, and key recommendations for future directions were proposed.

Research limitations/implications

The integration of Lean Manufacturing and I4.0 will eventually bring many benefits and offers superior and long-term competitive advantages. This research reveals the need for more analysis to thoroughly examine how this can be achieved in real life and promote operational changes that ensure enterprises run more sustainably.

Originality/value

The development of Lean Manufacturing and I4.0 integration is still in its infancy, with most articles in this field published in the past two years. The five main research themes identified through thematic synthesis are provided in the original contribution. This provides scholars better insight into the existing literature related to Lean Manufacturing and I4.0, further contributing to defining clear topics for future research opportunities. It also has important implications for industrialists, who can develop more profound and richer knowledge than Lean and I4.0, which would, in turn, help them develop more effective deployment strategies and have a positive commercial impact.

Details

International Journal of Lean Six Sigma, vol. 15 no. 5
Type: Research Article
ISSN: 2040-4166

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Article
Publication date: 8 November 2022

Sudhanshu Joshi, Manu Sharma, Shalini Bartwal, Tanuja Joshi and Mukesh Prasad

The study proposes to determine the impending challenges to lean integration with Industry 4.0 (I4.0) in manufacturing that aims at achieving desired operational performance…

878

Abstract

Purpose

The study proposes to determine the impending challenges to lean integration with Industry 4.0 (I4.0) in manufacturing that aims at achieving desired operational performance. Integrating lean and Industry 4.0 as the two industrial approaches is synergetic in providing operational benefits such as increasing flexibility, improving productivity, reducing cost, reducing delivery time, improving quality and value stream mapping (VSM). There is an urgent need to understand the integrated potential of OPEX strategies like lean manufacturing and also to determine the challenges for manufacturing SMEs and further suggest a strategic roadmap for the future.

Design/methodology/approach

The current work has used a combined approach on interpretative structural modeling (ISM) and fuzzy Matrice d'impacts croisés multiplication appliquée á un classment (MICMAC) approach to structure the multiple level analysis for the implementation challenges to integrate OPEX strategies with Industry 4.0.

Findings

The research has found that the indulgence of various implementation issues like lack of standardization, lack of vision and lack of trained support, all are the major challenges that inhibit the integration of OPEX strategies with I4.0 technologies in manufacturing.

Research limitations/implications

The research has investigated the internal factors acting as a roadblock to lean and Industry 4.0 adoption. Further studies may consider external factors to lean and Industry 4.0 implementation. Also, further research may consider other operational excellence approaches and extend further to relevant sectors.

Practical implications

This study provides the analysis of barriers that is useful for the managers to take strategic actions for implementing OPEX strategies with I4.0 in smart manufacturing.

Originality/value

The research determines the adoption challenges towards the integrated framework. This is the first study to explore challenges in integrating OPEX strategies with I4.0 technologies in manufacturing SMEs.

Details

The TQM Journal, vol. 36 no. 1
Type: Research Article
ISSN: 1754-2731

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Article
Publication date: 21 May 2021

Rohit Agrawal, Vishal Ashok Wankhede, Anil Kumar and Sunil Luthra

This work aims to review past and present articles about data-driven quality management (DDQM) in supply chains (SCs). The motive behind the review is to identify associated…

1108

Abstract

Purpose

This work aims to review past and present articles about data-driven quality management (DDQM) in supply chains (SCs). The motive behind the review is to identify associated literature gaps and to provide a future research direction in the field of DDQM in SCs.

Design/methodology/approach

A systematic literature review was done in the field of DDQM in SCs. SCOPUS database was chosen to collect articles in the selected field and then an SLR methodology has been followed to review the selected articles. The bibliometric and network analysis has also been conducted to analyze the contributions of various authors, countries and institutions in the field of DDQM in SCs. Network analysis was done by using VOS viewer package to analyze collaboration among researchers.

Findings

The findings of the study reveal that the adoption of data-driven technologies and quality management tools can help in strategic decision making. The usage of data-driven technologies such as artificial intelligence and machine learning can significantly enhance the performance of SC operations and network.

Originality/value

The paper discusses the importance of data-driven techniques enabling quality in SC management systems. The linkage between the data-driven techniques and quality management for improving the SC performance was also elaborated in the presented study.

Details

The TQM Journal, vol. 35 no. 1
Type: Research Article
ISSN: 1754-2731

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Article
Publication date: 13 September 2022

Abhishek Kashyap, Amarendra Kumar Yadav, Omkar Nandan Vatsa, Trivedh Naidu Chandaka and Om Ji Shukla

The purpose of this paper is to develop an interpretive structural modeling (ISM) model to investigate the critical success factors (CSF) and the extent of CSF's influence in the…

511

Abstract

Purpose

The purpose of this paper is to develop an interpretive structural modeling (ISM) model to investigate the critical success factors (CSF) and the extent of CSF's influence in the implementation of lean industry 4.0 in manufacturing supply chain.

Design/methodology/approach

The study has been carried out with the help of the latest literature followed by brainstorming sessions with experts. The experts were the managers from the industries, assistant professors, and research scholars from academia working in this domain. Finally, a structured model is formed using ISM methodology for the analysis of the CSFs followed by matrice d'impacts croisés multiplication appliquée á un classment (MIAMAC) Analysis for the validation of the model.

Findings

The study identifies robotics, virtual and augmented reality and cloud computing as the main CSFs which are responsible to drive all the identified CSFs. However the CSF professional training and development (PTD) has been identified as the weakest driver but having the highest dependent power.

Research limitations/implications

The study has included nine CSFs and the contextual relationships between the CSFs are based on the knowledge and experience of the experts, which may be biased. Moreover, the paper has covered the ISM approach, and the same thing can be validated using the fuzzy-ISM and other multi-criteria decision-making (MCDM) techniques.

Originality/value

This investigation of the CSFs in the lean industry 4.0 is original and the identified CSFs are the result of the literature reviews and an extensive discussion from the experts. The paper uses the complete experience of the respective experts to make this work more effective and original.

Details

Management of Environmental Quality: An International Journal, vol. 34 no. 4
Type: Research Article
ISSN: 1477-7835

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