Lean practices transfer in developed countries
a practical case in an electrical wires and cables company
DOI:
https://doi.org/10.31686/ijier.vol7.iss8.1631Keywords:
Electrical wires and cables company, Value Stream Mapping, Lean knowledge transferAbstract
Although Lean knowledge is widely spread worldwide bringing forth benefits to organizations, observable in the literature is that small-sized enterprises in developed countries do not usually apply this industrial management technique. Therefore, this article has sought to demonstrate that Lean Knowledge Transfer, through the university-enterprise cooperation, may reach expressive results in a wires and cables company. To achieve that, a product family largely impacting the production process has been selected in that company. Next, the tool Value Stream Mapping (VSM) has been used to visualize the current state and, in partnership with the company’s managers, idealize a future state of the process. With that, wastes have been found in the production process and Lean tools have been pointed out to reach improvements proposed in the future state. The results have shown a significant reduction in wastes of: movement of operators (50 and 40% in distances traveled), inventories (44 and 22% of copper), lead time (60 and 53% of the time) and the number of operators (39% in total). Thus, the conclusion is that these results corroborate the literature, where one may apply Lean knowledge transfer in different-sized enterprises so as to seek the reduction of wastes and improve the production process efficiently with the cooperation of universities.
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References
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[25] Iuga, M. V., & Kifor, C. V. (2014). Lean Manufacturing and its Transfer to Non-Japanese Organizations. Quality-access to success, 15 (139).
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[27] Vamsi Krishna Jasti, N., & Sharma, A. (2014). Lean manufacturing implementation using value stream mapping as a tool: A case study from auto components industry. International Journal of Lean Six Sigma, 5 (1), 89-116. https://10.1108/ijlss-04-2012-0002
[28] Kurtz, D. J., Forcellini, F. A., & Varvakis, G. (2014). O pensamento enxuto aplicado ao processo de transferência de conhecimento entre organizações: associação entre desperdícios e barreiras ao fluxo de conhecimento em uma cadeia produtiva. Revista ESPACIOS| Vol. 35 (Nº 2) Año 2014.
[29] Leite, H. D. R., & Vieira, G. E. (2015). Lean philosophy and its applications in the service industry: a review of the current knowledge. Production, 25(3), 529-541. https://10.1590/0103-6513.079012
[30] Borges Lopes, R., Freitas, F., & Sousa, I. (2015). Application of lean manufacturing tools in the food and beverage industries. Journal of technology management & innovation, 10 (3), 120-130. https://10.4067/s0718-27242015000300013
[31] Marksberry, P., Badurdeen, F., Gregory, B., & Kreafle, K. (2010). Management directed kaizen: Toyota's Jishuken process for management development. Journal of Manufacturing Technology Management, 21 (6), 670-686. https://10.1108/17410381011063987
[32] Massey, L., & Williams, S. (2005). CANDO: implementing change in an NHS Trust. International Journal of Public Sector Management, 18 (4), 330-349. https://10.1108/09513550510599256
[33] Melton, T. (2005). The benefits of lean manufacturing: what lean thinking has to offer the process industries. Chemical engineering research and design, 83 (6), 662-673. https://10.1205/cherd.04351
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[37] Pagani, R. N., Kovaleski, J. L., & Resende, L. M. (2015). Methodi Ordinatio: a proposed methodology to select and rank relevant scientific papers encompassing the impact factor, number of citation, and year of publication. Scientometrics, 105 (3), 2109-2135. https://10.1007/s11192-015-1744-x
[38] Piercy, N., & Rich, N. (2009). Lean transformation in the pure service environment: the case of the call service centre. International journal of operations & production management, 29 (1), 54-76. https://10.1108/01443570910925361
[39] Pinto, C. F., Coelho, S. M., Calado, R. D., & Silva, M. B. (2013). Access Improvement using Lean Healthcare for Radiation Treatment in a Public Hospital. IFAC Proceedings Volumes, 46 (24), 247-253. https://10.3182/20130911-3-br-3021.00048
[40] Samuel, D., Found, P., & Williams, S. J. (2015). How did the publication of the book The Machine That Changed The World change management thinking? Exploring 25 years of lean literature. International Journal of Operations & Production Management, 35 (10), 1386-1407. https://10.1108/ijopm-12-2013-0555
[41] Shan, S., Wang, L., Xin, T., & Bi, Z. (2013). Developing a rapid response production system for aircraft manufacturing. International Journal of Production Economics, 146 (1), 37-47. https://10.1016/j.ijpe.2012.12.006
[42] Singh, B., Garg, S. K., Sharma, S. K., & Grewal, C. (2010). Lean implementation and its benefits to production industry. International journal of lean six sigma, 1 (2), 157-168.
[43] Singh, H., & Singh, A. (2013). Application of lean manufacturing using value stream mapping in an auto-parts manufacturing unit. Journal of Advances in Management Research, 10 (1), 72-84. https://10.1108/09727981311327776
[44] Singh, H., Bahl, A., Kumar, A., & Mann, G. S. (2018). Materials and Information Flow Analysis and Optimization of Manufacturing Processes in MSMEs by the Application of Value Stream Mapping (VSM) Technique. Materials Today: Proceedings, 5 (14), 28420-28426. https://10.1016/j.matpr.2018.10.128
[45] Solding, P., & Gullander, P. (2009, December). Concepts for simulation based value stream mapping. In Winter Simulation Conference (pp. 2231-2237). Winter Simulation Conference. https://10.1109/wsc.2009.5429185
[46] Soliman, M., & Saurin, T. A. (2017). Lean production in complex socio-technical systems: A systematic literature review. Journal of Manufacturing Systems, 45, 135-148.
[47] Teichgräber, U. K., & de Bucourt, M. (2012). Applying value stream mapping techniques to eliminate non-value-added waste for the procurement of endovascular stents. European journal of radiology, 81 (1), e47-e52. https://10.1016/j.ejrad.2010.12.045
[48] World Bank, World Development Indicators. (2019). Global Economic Prospects (% of population) [Data file]. Retrieved from https://www.worldbank.org/en/publication/global-economic-prospects
[49] Tyagi, S., Choudhary, A., Cai, X., & Yang, K. (2015). Value stream mapping to reduce the lead-time of a product development process. International Journal of Production Economics, 160, 202-212. https://10.1016/j.ijpe.2014.11.002
[50] Verma, N., & Sharma, V. (2016). Energy value stream mapping a tool to develop green manufacturing. Procedia Engineering, 149, 526-534. https://10.1016/j.proeng.2016.06.701
[51] Vigour, C. (2015). Professions in Policy and Knowledge Transfer: Adaptations of Lean Management, and Jurisdictional Conflict in a Reform of the French Public Service. International Journal of Sociology, 45 (2), 112-132. https://10.1080/00207659.2015.1061855
[52] Yang, C. C., & Yang, K. J. (2013). An integrated model of the Toyota production system with total quality management and people factors. Human Factors and Ergonomics in Manufacturing & Service Industries, 23 (5), 450-461. https://10.1002/hfm.20335
[2] Ali, N. B., Petersen, K., & De França, B. B. N. (2015). Evaluation of simulation-assisted value stream mapping for software product development: Two industrial cases. Information and software technology, 68, 45-61. https://doi.org/10.1016/j.infsof.2015.08.005
[3] Andrade, P. F., Pereira, V. G., & Del Conte, E. G. (2016). Value stream mapping and lean simulation: a case study in automotive company. The International Journal of Advanced Manufacturing Technology, 85 (1-4), 547-555. https://10.1007/s00170-015-7972-7
[4] Antony, J. (2011). Six Sigma vs Lean: Some perspectives from leading academics and practitioners. International Journal of Productivity and Performance Management, 60 (2), 185-190. http://dx.doi.org/10.1108/17410401111101494
[5] Rahani, A. R., & Al-Ashraf, M. (2012). Production flow analysis through value stream mapping: a lean manufacturing process case study. Procedia Engineering, 41, 1727-1734. https://10.1016/j.proeng.2012.07.375
[6] Barth Bartz, A. P., Weise, A. D., & Ruppenthal, J. E. (2013). Aplicação da manufatura enxuta em uma indústria de equipamentos agrícolas. Ingeniare. Revista chilena de ingeniería, 21 (1), 147-158. https://10.4067/s0718-33052013000100013
[7] Ben Fredj-Ben Alaya, L. (2016). VSM a powerful diagnostic and planning tool for a successful Lean implementation: a Tunisian case study of an auto parts manufacturing firm. Production Planning & Control, 27 (7-8), 563-578. https://10.1080/09537287.2016.1165305
[8] Bonavia, T., & Marin, J. A. (2006). An empirical study of lean production in the ceramic tile industry in Spain. International Journal of Operations & Production Management, 26 (5), 505-531. https://10.1108/01443570610659883
[9] Camuffo, A., Secchi, R., & Paolino, C. (2014). The Diffusion of Lean Operations Practices in MNCs: A Knowledge-Based, Plant Level, Cross-Firm Study. In Orchestration of the Global Network Organization (pp. 43-74). Emerald Group Publishing Limited. https://10.1108/s1571-502720140000027004
[10] Carmignani, G. (2017). Scrap value stream mapping (S-VSM): a new approach to improve the supply scrap management process. International Journal of Production Research, 55 (12), 3559-3576. https://10.1080/00207543.2017.1308574
[11] Chatterjee, R., Sharma, V., Mukherjee, S., & Kumar, S. (2014). Value stream mapping based on energy and cost system for biodiesel production. International Journal of Sustainable Manufacturing, 3 (2), 95-115. https://10.1504/ijsm.2014.062492
[12] Chen, L., & Meng, B. (2010). The application of value stream mapping based lean production system. International journal of business and management, 5 (6), 203. https://10.5539/ijbm.v5n6p203
[13] D’Andreamatteo, A., Ianni, L., Rangone, A., Paolone, F., & Sargiacomo, M. (2019). Institutional pressures, isomorphic changes and key agents in the transfer of knowledge of Lean in Healthcare. Business Process Management Journal, 25 (1), 164-184. https://10.1108/bpmj-06-2017-0174
[14] Danese, P., Romano, P., & Boscari, S. (2017). The transfer process of lean practices in multi-plant companies. International Journal of Operations & Production Management, 37 (4), 468-488. https://10.1108/ijopm-12-2014-0571
[15] Das, B., Venkatadri, U., & Pandey, P. (2014). Applying lean manufacturing system to improving productivity of airconditioning coil manufacturing. The International Journal of Advanced Manufacturing Technology, 71 (1-4), 307-323. https://10.1007/s00170-013-5407-x
[16] De Mattos, F. A. M., Neto, J. H., Oliveira, F. C., & Machado, D. C. (2018). Auge E Declínio Dos Indicadores Do Mercado De Trabalho Brasileiro: Da Era Lulista À Política Econômica Da “Ponte Para O Futuro”. Revista NECAT-Revista do Núcleo de Estudos de Economia Catarinense, 7(13), 29-53.
[17] Demeter, K., & Losonci, D. (2019). Transferring lean knowledge within multinational networks. Production Planning & Control, 30 (2-3), 211-224. https://doi.org/10.1080/09537287.2018.1534272
[18] Dennis, P. (2009). Produção lean simplificada. Bookman Editora.
[19] Douglas Sears, H. (2009). Bon Secours Health System integrates Lean Six Sigma and knowledge transfer to drive clinical and operational excellence. Global Business and Organizational Excellence, 28 (6), 31-45. https://10.1002/joe.20286
[20] Fraser, N., & Fraser, J. (2009). Lean Six Sigma applied to an accounting process within a client of a commercial finance organisation–an empirical case study. International Journal of Six Sigma and Competitive Advantage, 5 (3), 272-289. https://10.1504/ijssca.2009.028097
[21] Friedrichsdorf, S. J., Eull, D., Weidner, C., & Postier, A. (2018). A hospital-wide initiative to eliminate or reduce needle pain in children using lean methodology. Pain reports, 3 (Suppl 1). https://10.1097/pr9.0000000000000671
[22] Gjeldum, N., Mladineo, M., & Veza, I. (2016). Transfer of model of innovative smart factory to croatian economy using lean learning factory. Procedia CIRP, 54, 158-163. https://10.1016/j.procir.2016.06.096
[23] Hassanain, M. (2017). An overview of the performance improvement initiatives by the ministry of Health in the Kingdom of Saudi Arabia. INQUIRY: The Journal of Health Care Organization, Provision, and Financing, 54, 0046958017707872. https://10.1177/0046958017707872
[24] H. Netland, T., & Aspelund, A. (2014). Multi-plant improvement programmes: a literature review and research agenda. International Journal of Operations & Production Management, 34 (3), 390-418. https://10.1108/ijopm-02-2012-0087
[25] Iuga, M. V., & Kifor, C. V. (2014). Lean Manufacturing and its Transfer to Non-Japanese Organizations. Quality-access to success, 15 (139).
[26] Jacobs, B. W., Swink, M., & Linderman, K. (2015). Performance effects of early and late Six Sigma adoptions. Journal of Operations Management, 36, 244-257. https://10.1016/j.jom.2015.01.002
[27] Vamsi Krishna Jasti, N., & Sharma, A. (2014). Lean manufacturing implementation using value stream mapping as a tool: A case study from auto components industry. International Journal of Lean Six Sigma, 5 (1), 89-116. https://10.1108/ijlss-04-2012-0002
[28] Kurtz, D. J., Forcellini, F. A., & Varvakis, G. (2014). O pensamento enxuto aplicado ao processo de transferência de conhecimento entre organizações: associação entre desperdícios e barreiras ao fluxo de conhecimento em uma cadeia produtiva. Revista ESPACIOS| Vol. 35 (Nº 2) Año 2014.
[29] Leite, H. D. R., & Vieira, G. E. (2015). Lean philosophy and its applications in the service industry: a review of the current knowledge. Production, 25(3), 529-541. https://10.1590/0103-6513.079012
[30] Borges Lopes, R., Freitas, F., & Sousa, I. (2015). Application of lean manufacturing tools in the food and beverage industries. Journal of technology management & innovation, 10 (3), 120-130. https://10.4067/s0718-27242015000300013
[31] Marksberry, P., Badurdeen, F., Gregory, B., & Kreafle, K. (2010). Management directed kaizen: Toyota's Jishuken process for management development. Journal of Manufacturing Technology Management, 21 (6), 670-686. https://10.1108/17410381011063987
[32] Massey, L., & Williams, S. (2005). CANDO: implementing change in an NHS Trust. International Journal of Public Sector Management, 18 (4), 330-349. https://10.1108/09513550510599256
[33] Melton, T. (2005). The benefits of lean manufacturing: what lean thinking has to offer the process industries. Chemical engineering research and design, 83 (6), 662-673. https://10.1205/cherd.04351
[34] Meudt, T., Metternich, J., & Abele, E. (2017). Value stream mapping 4.0: Holistic examination of value stream and information logistics in production. CIRP Annals, 66 (1), 413-416. https://10.1016/j.cirp.2017.04.005
[35] Morlock, F., & Meier, H. (2015). Service value stream mapping in industrial product-service system performance management. Procedia CIRP, 30, 457-461. https://10.1016/j.procir.2015.02.128
[36] Murugananthan, V. R., Govindaraj, K., & Sakthimurugan, D. (2014). Process planning through value stream mapping in foundry. International Journal of Innovative Research in Science, Engineering and Technology, 3 (3), 1140-1143.
[37] Pagani, R. N., Kovaleski, J. L., & Resende, L. M. (2015). Methodi Ordinatio: a proposed methodology to select and rank relevant scientific papers encompassing the impact factor, number of citation, and year of publication. Scientometrics, 105 (3), 2109-2135. https://10.1007/s11192-015-1744-x
[38] Piercy, N., & Rich, N. (2009). Lean transformation in the pure service environment: the case of the call service centre. International journal of operations & production management, 29 (1), 54-76. https://10.1108/01443570910925361
[39] Pinto, C. F., Coelho, S. M., Calado, R. D., & Silva, M. B. (2013). Access Improvement using Lean Healthcare for Radiation Treatment in a Public Hospital. IFAC Proceedings Volumes, 46 (24), 247-253. https://10.3182/20130911-3-br-3021.00048
[40] Samuel, D., Found, P., & Williams, S. J. (2015). How did the publication of the book The Machine That Changed The World change management thinking? Exploring 25 years of lean literature. International Journal of Operations & Production Management, 35 (10), 1386-1407. https://10.1108/ijopm-12-2013-0555
[41] Shan, S., Wang, L., Xin, T., & Bi, Z. (2013). Developing a rapid response production system for aircraft manufacturing. International Journal of Production Economics, 146 (1), 37-47. https://10.1016/j.ijpe.2012.12.006
[42] Singh, B., Garg, S. K., Sharma, S. K., & Grewal, C. (2010). Lean implementation and its benefits to production industry. International journal of lean six sigma, 1 (2), 157-168.
[43] Singh, H., & Singh, A. (2013). Application of lean manufacturing using value stream mapping in an auto-parts manufacturing unit. Journal of Advances in Management Research, 10 (1), 72-84. https://10.1108/09727981311327776
[44] Singh, H., Bahl, A., Kumar, A., & Mann, G. S. (2018). Materials and Information Flow Analysis and Optimization of Manufacturing Processes in MSMEs by the Application of Value Stream Mapping (VSM) Technique. Materials Today: Proceedings, 5 (14), 28420-28426. https://10.1016/j.matpr.2018.10.128
[45] Solding, P., & Gullander, P. (2009, December). Concepts for simulation based value stream mapping. In Winter Simulation Conference (pp. 2231-2237). Winter Simulation Conference. https://10.1109/wsc.2009.5429185
[46] Soliman, M., & Saurin, T. A. (2017). Lean production in complex socio-technical systems: A systematic literature review. Journal of Manufacturing Systems, 45, 135-148.
[47] Teichgräber, U. K., & de Bucourt, M. (2012). Applying value stream mapping techniques to eliminate non-value-added waste for the procurement of endovascular stents. European journal of radiology, 81 (1), e47-e52. https://10.1016/j.ejrad.2010.12.045
[48] World Bank, World Development Indicators. (2019). Global Economic Prospects (% of population) [Data file]. Retrieved from https://www.worldbank.org/en/publication/global-economic-prospects
[49] Tyagi, S., Choudhary, A., Cai, X., & Yang, K. (2015). Value stream mapping to reduce the lead-time of a product development process. International Journal of Production Economics, 160, 202-212. https://10.1016/j.ijpe.2014.11.002
[50] Verma, N., & Sharma, V. (2016). Energy value stream mapping a tool to develop green manufacturing. Procedia Engineering, 149, 526-534. https://10.1016/j.proeng.2016.06.701
[51] Vigour, C. (2015). Professions in Policy and Knowledge Transfer: Adaptations of Lean Management, and Jurisdictional Conflict in a Reform of the French Public Service. International Journal of Sociology, 45 (2), 112-132. https://10.1080/00207659.2015.1061855
[52] Yang, C. C., & Yang, K. J. (2013). An integrated model of the Toyota production system with total quality management and people factors. Human Factors and Ergonomics in Manufacturing & Service Industries, 23 (5), 450-461. https://10.1002/hfm.20335
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das Neves Almeida, M., Carvalho da Silva, F. ., Kovaleski, J. L. ., da Conceição Pereira, P. F. ., & Carvalho Lima, B. B. (2019). Lean practices transfer in developed countries: a practical case in an electrical wires and cables company. International Journal for Innovation Education and Research, 7(8), 12-31. https://doi.org/10.31686/ijier.vol7.iss8.1631
