Dinesh Seth

Application of value stream mapping (VSM) for minimization of wastes in the processing side of supply chain of cottonseed oil industry in Indian context

Purpose – The purpose of this paper is to identify and address various wastes in the supply chain of the edible cottonseed oil industry (specifically the processing side) using a value stream mapping (VSM) approach to improve productivity and capacity utilization in an Indian context.Design/methodology/approach – Critical observations and interviewing techniques were used with open‐ended questions to understand the processes involved in the value chain of the cottonseed oil industry. Different chain links/members were investigated through personal visits and discussions. VSM is applied as an approach to the industry to identify and remove non‐value‐adding (NVA) activities.Findings – Major findings obtained from the study are as follows. There is an excess cumulative inventory of 244 days in the whole supply chain. The industry is highly fragmented with a large number of small players present, which hampers the use of economies of scale. There are NVA activities present in the supply chain such as the movi...

Critical success factors for Lean Six Sigma in SMEs (small and medium enterprises)

Purpose – The purpose of this paper is to identify and list critical success factors (CSFs) of Lean Six Sigma (LSS) framework affecting and influencing quality, operational and financial performance of small and medium enterprises (SMEs). It also intends to guide researchers and practitioners in selecting appropriate set of CSFs for empirical studies, developing frameworks and to ensure effective implementation experience of LSS. Design/methodology/approach – It systematically reviews literature on CSFs and Indian experience regarding LSS. It uses exploratory approach for data collection and documents various studies depicting both manufacturing and service experiences by using time tested statistical tools to prioritize CSFs, which critically influence LSS implementation. Findings – The study guides and facilitates researchers and practitioners in using the most appropriate set of CSFs for empirical studies and in developing/modifying/reviewing application frameworks. It also guides implementation experi...

Application of value stream mapping (VSM) for lean and cycle time reduction in complex production environments: a case study

Abstract The application of VSM is a proven approach for lean-based improvements. Typically, this becomes challenging, when applied for complex production environments. The purpose of this research is to demonstrate, how with some approximations and simplifications in VSM application, lean can be successfully achieved in these environments. The research follows case study method and systematically guides about the segregation and treatment of non-value-adding(NVA) and value-adding (VA) activities of heavy-duty industrial power transformer making process. The focal company operates in engineer to order (ETO) and high-mix low-volume (HMLV) environments. With a research team using gemba walks and systematic questioning technique, relevant data were collected for mapping. Taguchi method was also applied for one of the critical steps, which was influencing cycle time and energy requirements. The generalisable findings endorse the strengths of approach for lean by addressing wastes and cycle time reduction. The study establishes that VSM application-based lean messages remain same for both simple and complex environments. It also exposes that non-compliance of ‘VSM assumptions’ and ‘micro-concepts’ are the root causes for application complexities. The study also offers useful insights and practical guidelines to facilitate lean in ETO, construction and HMLV production environments.

Application and evaluation of packaging postponement strategy to boost supply chain responsiveness: a case study

The purpose of this study is to demonstrate how packaging postponement can be effectively leveraged in a dynamically changing diverse retail market where responsiveness is key. The study also guides about the empirical evaluation of how packaging postponement affects the performance in the sanitary pads supply chain by considering operating measures. The focal company belongs to the Indian Fast Moving Consumer Goods sector, hygiene products category. It examines the measures that are critical to a responsive supply chain and presents a comparative analysis of selected measures before and after implementation. The findings illustrate that the packaging postponement not only improves competitive advantage but also significantly contributes to improving product proliferation and supply chain responsiveness. The study provides understanding of drivers and obstacles for packaging postponement strategy with operational insights about ‘how-to’ implement. Most of modelling-based research studies justify the adoption of postponement through savings in inventory only and underplay on other operating measures. While justifying, studies emphasise ‘form’/manufacturing aspects and underestimate the packaging aspects of postponement. This paper addresses these gap areas by systematically highlighting prerequisites and demonstrates the benefits of adopting a packaging strategy to handle variety and responsiveness in an emerging economy.

An integrated resource allocation and distribution model for pre-disaster planning

We model a disaster preparedness problem for the supply of a commodity.We consider an integrated pre- and post-disaster preparedness planning model.The use of multiple supply points reduces supply deprivations at the demand points.Deprivation cost structure significantly affect the proportion of pre- and post-disaster allocations. In this paper, a three-echelon network model is proposed for integrated emergency preparedness and response planning for the distribution of emergency supplies. The model minimizes the social cost to identify a set of potential supply points (SPs) at the highest echelon, where supply items are consolidated and sent to the prepositioning facilities. The sum of logistics and deprivation costs incurred by the population due to the lack of access to goods or services, is considered as the social cost in this model. The deprivation cost is assumed to increase exponentially with the deprivation time. The model also considers pre-disaster and post-disaster purchasing decisions at the SPs, and allows direct shipments from SPs and prepositioned facilities to the demand points. Numerical analysis shows that multiple supply sources can ensure efficient distribution of the supplies and reduce the deprivation costs. The results also indicate that partial prepositioning and post-disaster purchasing can reduce the shortage in emergency supplies.

An empirical investigation of critical success factors and performance measures for green manufacturing in cement industry

Purpose The purpose of this paper is to aim for the development and analysis of green manufacturing (GM)-based framework on the identified critical success factors (CSFs) and performance measures (PMs) in the context of the Indian cement industry. Design/methodology/approach The research follows survey method for data collection. For framework development, it uses factor analysis on the identified CSFs and regression along with the appropriate measures for checking statistical consistency and validity. Findings This is the first research towards GM framework for the Indian cement industry. Till date, no framework is available which could guide researchers and practitioners of this environment unfriendly industry. Study exposes lack of connectivity between CSFs and PMs for a GM framework and highlights weaknesses of cement industry in this regard. It offers a generalised GM framework linking PMs with top management, human resource management, organisational culture, green practices, process management and supply chain management. Practical implications The framework is expected to help both researchers and practitioners from cement, construction and other industries who are serious towards GM implementation and are looking for appropriate mechanism. This framework if implemented properly will result in enhanced productivity. Originality/value This work is one of the few and pioneering efforts to investigate GM linking CSFs and PMs in Indian manufacturing sectors and the first in cement industry. Not many studies are available in the context of cement industry, which is the lifeblood of infrastructure and construction sectors. The importance of the work increases as it is conducted in the Indian context, which is undeniably an important economy of the world.

Analysis of research trends and constructs in context to lean six sigma frameworks

Purpose The literature of lean six sigma (LSS) is flooded with frameworks. But to date, there has been no attempt to expose the inconsistencies in the existing frameworks and associated research trends. The purpose of this paper is to critically review 26 LSS frameworks and highlight inconsistencies. The study also helps in analysing research trends and constructs of LSS frameworks, and facilitates new applications. Design/methodology/approach It uses Scopus database and finalises 26 frameworks in the LSS domain considering a timeframe from 2000 to 2017, using a structured literature review approach and involving domain experts. It uses a battery of systematic requirements-based questions to understand trends and covers building blocks/constructs also. Findings It reveals inconsistencies at three different stages, namely, the framework stage, usage stage capturing existing research trends and construct stage. It also offers details at building block/construct level. Thus, it offers guidance in reducing inconsistencies and possible modifications in the existing frameworks. It not only exposes existing constructs and sub-constructs but also guides about the new upcoming changes in the business influencing the LSS domain. It also educates about the strengths and weaknesses of each framework. Research limitations/implications This study tries to reduce inconsistencies, but does not offer new generalised or sector-specific framework. Practical implications This study will assist for modification/corrections in the existing frameworks by reducing inconsistencies and will encourage new frameworks to facilitate applications. Originality/value This is a unique study which offers frameworks-based review, portrays research trends and guides about constructs of a framework by exposing inconsistencies at each stage. It helps in reducing inconsistencies and offers guidance regarding modifications in the LSS framework considering upcoming challenges.

Application of hybrid framework to facilitate lean six sigma implementation: a manufacturing company case experience

Abstract This study aims to propose a hybrid framework for lean six sigma (LSS) based on the prioritisation of barriers and solution approaches, to facilitate hassles free applications for handling the challenges of wastes reduction and quality improvement. The study identifies 27 LSS barriers and 22 solution approaches through literature review and utilises feedback from industry experts. For framework, study uses fuzzy AHP-PROMETHEE to prioritise LSS barriers and solution approaches. Incorporating fuzzy sets in analytical hierarchy process (AHP) ensures the optimality of barrier weights. Whereas, preference ranking organisation method for enrichment of evaluations (PROMETHEE) helps in pairwise comparisons of solution approaches with respect to each LSS barrier, facilitating fair judgements. This research guides regarding the development of framework and checks its suitability and robustness through case application of an Indian manufacturing organisation. Authors expect that researchers and practitioners will find study useful for LSS and multi criteria decision making(MCDM) domains.

Application of Petri nets towards improved utilization of machines in job shop manufacturing environments

Purpose The purpose of this paper is to demonstrate the use of Petri nets in a job shop setup for the improvement in the utilization of machines. Design/methodology/approach The study discusses concepts such as reachable state, token and matrix equations set, and demonstrates the improvements in machines’ utilization in a job shop. It makes use of algorithms to generate reachable markings to obtain utilization. The study not only describes the application of theory, but also extends the body of knowledge on Petri nets and job shops. Findings In this study, machines’ utilization has been studied in a job shop with six machines and eight products. The study finds that substantial utilization improvement in job shop set up can be obtained through the application of Petri nets. The study also exposes that Petri nets are mostly used for machines, jobs and tools scheduling problems, but its use in machines’ utilization is neglected. The framework and application presented here along with generalizable findings, is the first to report about machine utilization improvement in job shop manufacturing environment. Practical implications Job shops are characterized by high unit production cost, low investments, low volume and high variety, complex flows, flexible and skilled work force, general purpose machines, high material handling; resulting in poor utilization of machines. Therefore, the findings of this study can help in reducing such costs through better machine utilization. This can help in increasing the competitiveness of the companies. Originality/value The contribution of study lies in investigating and improving stage wise utilization in a job shop setup. It has never been reported before.

Impact of competitive conditions on supplier evaluation: a construction supply chain case study

Abstract This research proposes a multi-criteria decision-making (MCDM) framework and demonstrates the impact of competitive conditions on supplier evaluation process for construction supply chains. The paper focuses on the supply chain of a large-scale housing project in order to illustrate the role of competitive capability and suppliers’ profile and its influence on supplier evaluation based on prevailing supply/market conditions. Various scenarios are investigated to demonstrate the impact of competition on supplier evaluation. The contribution of the study lies in highlighting the impact of supply/market conditions on MCDM decisions causing supplier evaluation ‘imbalance’ and MCDM usage. It is expected that the study will be useful for project management, construction, supply chain management, sourcing professionals. The findings of the study are generalisable to projects-based situations such as petroleum refinery and ship building where bill of materials typically consists of thousands of items and a large number of suppliers are involved.