Daryl Powell

Lean production and ERP systems in small- and medium-sized enterprises: ERP support for pull production

It is generally accepted that lean production improves manufacturing processes through the systematic application of lean practices, and equally assumed that present day IT systems, particularly ERP systems, are essential for companies seeking efficiency through organisational integration. Though lean production and ERP co-exist in many companies today, there is an ongoing argument in the scientific literature as to whether or not ERP systems can be used to support lean production principles, particularly pull production. By applying a multiple-case-study approach, we assess the functionality offered by ERP systems to support pull production. We develop and apply a capability maturity model that can be used to assess the extent to which the usage of a companys current ERP system supports pull production practices and to suggest modifications to the ERP system in order to better serve the companys pull system. We focus on the application of lean production and ERP within small- and medium-sized enterprises, as in these companies decisions on lean and ERP are generally made by the same decision maker, which improves construct validity.

ERP systems in lean production: new insights from a review of lean and ERP literature

Purpose – Faced with increasing global competition and growing customer expectations, manufacturers looking for significant performance improvements often look to one of the two choices: implementing an enterprise resource planning (ERP) system, or applying the tools and techniques associated with lean production. In fact, many companies are today applying both approaches in an attempt to realise competitive advantage in the global marketplace. However, there seems to be an ongoing debate within the academic literature as to whether lean and ERP are complimentary or contradictory technologies. This paper aims to present a thorough and critical review of literature with the objective of bringing out pertinent factors and useful insights into the role and implications of ERP systems in lean production and to develop a research framework that can be used by researchers and practitioners for studying the value of integrating ERP with lean. Design/methodology/approach – The research methodology employed is lit...

The Application of Lean Production Control Methods within a Process-Type Industry: The Case of Hydro Automotive Structures

Lean production has lead to substantial improvements in performance across many industries and is widely implemented today. Certain aspects of lean such as the focus on workplace organisation (5S) and total productive maintenance (TPM) have been applied to all types of industrial processes, while lean production control methods have mostly been applied in discrete and repetitive, assembly-type production. We believe that the real benefits of lean, for example throughput time and inventory reduction, are only realised when lean production control methods are implemented effectively. Therefore, we investigate the traditional lean production control methods of Heijunka and Kanban, and evaluate the concept of every product every (EPE) as an alternative lean production control method for the process-type industries.

RFID for the extended lean enterprise

Purpose – In the traditional sense, information technology has often been viewed as a contributor to waste within lean production. However, as the business world changes and competition from low‐cost countries increases, new models must be developed which deliver competitive advantage by combining contemporary technological advances with the lean paradigm. The purpose of this paper is therefore to contribute within this area, and it aims to evaluate the supporting role of radio frequency identification (RFID) technology in the context of lean thinking. The paper also aims to consider the application of RFID in order to revolutionize the lean paradigm, and to propose a framework for the use of RFID in order to create the extended lean enterprise, which the authors suggest can improve the competitiveness of manufacturing supply chains.Design/methodology/approach – The papers applied research methodology is case study. Having first explored the relevant literature surrounding the topic, the paper presents a...

Lean Six Sigma and environmental sustainability: the case of a Norwegian dairy producer

Purpose The purpose of this paper is to investigate the application of Lean Six Sigma (LSS) in the continuous process industry, taking an insight into the food processing industry; and to evaluate the impact of LSS on environmental sustainability. The authors present observations and experiences from the application of LSS at a Norwegian dairy producer, with the aim of bringing out pertinent factors and useful insights that help us to understand how LSS can contribute toward greater environmental sustainability in this industry type, something that is so far lacking in the extant literature. Design/methodology/approach The authors adopt a single, longitudinal field study approach as we observe an entire cycle of the VSM-DMAIC (value stream mapping-define, measure, analyze, improve and control) LSS process, which evolved over a six-month period at the dairy. Findings The authors highlight some of the important elements that should be considered when using LSS as a contributor toward greater environmental sustainability in fresh-food supply chains. The authors also present some of the specific outcomes and key success criteria that became apparent to the implementation team following the deployment of the VSM-DMAIC approach. Originality/value The authors demonstrate how LSS can be applied in the food processing industry as a contributor to greater environmental sustainability. The authors also make useful reflections regarding the success criteria that can be used by researchers and practitioners for the effective deployment of such an approach, particularly in the continuous process industry.

Exploring the archetypes of engineer-to-order: an empirical analysis

Purpose – The purpose of this paper is to conceptualize archetypes of engineer-to-order (ETO) to support companies in determining the appropriate degree of design standardization and automation, and as a result achieve superior performance. Products of ETO manufacturers are classified in a 2×2 matrix using annual units sold and engineering complexity as dimensions. Design/methodology/approach – This research adopted a theory refining approach based on multiple case studies. Seven ETO manufacturers from different industry sectors participated in the study. Data collection was primarily based on a series of in-depth interviews supported by observations and archival sources. Findings – The paper proposes four distinct archetypes of ETO (complex, basic, repeatable, and non-competitive) and empirically validates three of them. The organizational structures and processes most suitable for the different archetypes are described, and standardization and automation strategies are linked to the quadrants of the mat...

Using Lean Principles to Drive Operational Improvements in Intermodal Container Facilities: A Conceptual Framework

Purpose – The purpose of this paper is to explore the use of lean principles to drive operational improvements in intermodal container facilities. Intermodal terminals have an important role in today’s globally complex supply networks. In the case of bottleneck-derived terminalization, operational issues such as achieving effective material flow remains a significant and common challenge. To assist with such challenges, the paper develops a conceptual framework built on the principles of lean. Design/methodology/approach – In this paper, a theory-building approach is adopted and a lean terminalization framework developed by combining aspects of lean- and intermodal transport theory with practical insights. The framework was developed in conjunction with two intermodal container facilities within the Scandinavian region. Findings – The conceptual framework demonstrates how lean approaches can be used to identify improvement areas, as well as to develop solutions for improved material flow in the context of...

ERP Support for Lean Production

In the traditional sense, IT has often been viewed as a contributor to waste within lean production. However, as the business world changes and competition from low-cost countries increases, new models must be developed which deliver competitive advantage by combining contemporary technological advances with the lean paradigm. By applying an action research approach, this paper evaluates the support functionality of ERP systems for lean production. We address the fundamental principles of lean production in comparison with the functionality and modules of a contemporary ERP system.

ICT-Enabled Integrated Operations: Towards a Framework for the Integration of Manufacturing- and Maintenance Planning and Control

With the onset of increased competitive pressures from the likes of globalisation and various other factors, there has recently been a greater focus on the systematic integration of operations within and beyond enterprises. One such area has been the integration of maintenance planning and execution with the planning and control of manufacturing. Such a novel concept is denoted as Integrated Planning (IPL). In this paper we investigate developments within this area, and propose a conceptual framework which should be used to guide subsequent advances in the field.

Sustainable Food Supply Chains: Towards a Framework for Waste Identification

Reduction of waste in food supply chains is an important sustainability issue. More efficient utilisation and management of the resources and values created in food supply chains can contribute to improving competitiveness, and environmental and social responsibility. This study uses the seven wastes approach from lean theory to classify categories of waste in fresh food supply chains and to identify at which stage of the supply chain waste occur. A case is used to illustrate the applicability of the classification. The analysis identifies four categories of waste in the fresh food supply chain; time, distance, energy and mass. The study indicates that the majority of waste is hidden in time, energy and mass categories, related to overproduction, defects and transportation.