Jose Arturo Garza-Reyes

The impact of lean methods and tools on the operational performance of manufacturing organisations

Evidence suggests that lean methods and tools have helped manufacturing organisations to improve their operations and processes. However, the real effect of these methods and tools on contemporary measures of operational performance, i.e. cost, speed, dependability, quality and flexibility, is still unclear. This paper investigates the impact of five essential lean methods, i.e. JIT, autonomation, kaizen, total productive maintenance (TPM) and value stream mapping (VSM), on these measures. A linear regression analysis modelled the correlation and impact of these lean practices on the operational performance of 140 manufacturing organisations around the world. In addition, structural equation modelling (SME) was used to cross verify the findings of the regression and correlation analyses. The results indicate that JIT and automation have the strongest significance on operational performance while kaizen, TPM and VSM seem to have a lesser, or even negative, effect on it. This paper provides further evidence regarding the effects that lean practices have on the performance of organisations and thus the research offers companies, and their managers, a better understanding of the relationship between the lean strategy and the performance of their operations.

Lean Production, Market Share and Value Creation in the Agricultural Machinery Sector in Brazil

By adopting Lean Manufacturing firms wants to see the value created in its results at the bottom line. The agricultural machinery and implements sector in Brazil had experienced in Lean and saw its results affected by the program. Using an established analytical model, the paper tests three hypotheses: H1: firms with a high degree of management commitment to the program simultaneously support this commitment with investments in support of the plant infrastructure and problem-solving groups; H2: firms that adopt lean principles have made changes in the direction of these principles; H3: firms that made continuous investments in plant infrastructure in to support lean principles have better performances. All hypotheses H1, H2 and H3 were fully accepted and corroborated.

Overall equipment effectiveness (OEE) and process capability (PC) measures: A relationship analysis

Purpose – Overall equipment effectiveness (OEE) and process capability (PC) are commonly used and well‐accepted measures of performance in industry. These measures, however, are traditionally applied separately and with different purposes. The purpose of this paper is to investigate the relationship between OEE and PC, how they interact and impact each other, and the possible effect that this relationship may have on decision making.Design/methodology/approach – The paper reviews the OEE and PC background. Then, a discrete‐event simulation model of a bottling line is developed. Using the model, a set of experiments are run and the results interpreted using graphical trend and impact analyses.Findings – The paper demonstrates the relationship between OEE and PC and suggests the existence of a “cut‐off point” beyond which improvements in PC have little impact on OEE.Practical implications – PC uses the capability indices (CI) to help in determining the suitability of a process to meet the required quality s...

Green lean and the need for Six Sigma

Purpose – The purpose of this paper is to critically review the green lean approach and highlight its limitations; examine the compatibility of the green, lean and Six Sigma concepts; and propose Six Sigma, and specially its problem-solving methodology DMAIC, as an approach to help enhancing the effectiveness of green lean initiatives. Historically, profitability and efficiency, and more recently customer satisfaction, quality and responsiveness objectives have been the prevailing interest for organisations. However, the move towards greener operations and products has forced companies to seek alternatives to combine these with green objectives and initiatives. Green lean is the result of this combination. Thus, the paper conceptually proposes Green Lean Six Sigma. Design/methodology/approach – To do this, a systematic literature review (SLR) of the subjects under investigation was conducted. Findings – The SLR indicated that the green lean integration may have inherited the same limitations as the indivi...

Prioritisation of operations improvement projects in the European manufacturing industry

To improve their competitive ability, organisations are turning towards implementing improvements into their operations and processes. Whilst operations improvement projects are often identified with relative ease, resource constraints limit the ability of organisations to conduct them simultaneously. This paper supports the limited empirical research on prioritisation of improvement initiatives by investigating how European manufacturing organisations conduct this activity. To do this, four hypotheses and two research questions were formulated and tested using a combination of descriptive statistics and two proportion T-tests, while data was collected through a survey questionnaire responded by 203 organisations. The results highlight the importance of objectively prioritising improvement projects and establish that the adoption of this method increases through the implementation of improvement methodologies, especially those that stipulate the use of objective methods towards project prioritisation. In this way, Six Sigma is defined as the most influential improvement methodology for supporting the use of objective prioritisation approaches. The paper also identifies the reasons as to why organisations adopt subjective over objective prioritisation methods, and the most common approaches used by large organisations and small and medium enterprises. This research provides organisations, and their managers, with a better understanding of the different factors that affect this key aspect of operations improvement projects.

A Six Sigma and DMAIC application for the reduction of defects in a rubber gloves manufacturing process

Purpose – In this era of globalisation, as competition intensifies, providing quality products and services has become a competitive advantage and a need to ensure survival. The Six Sigmas problem-solving methodology DMAIC has been one of the several techniques used by organisations to improve the quality of their products and services. This paper aims to demonstrate the empirical application of Six Sigma and DMAIC to reduce product defects within a rubber gloves manufacturing organisation. Design/methodology/approach – The paper follows the DMAIC methodology to systematically investigate the root cause of defects and provide a solution to reduce/eliminate them. In particular, the design of experiments, hypothesis testing and two-way analysis of variance techniques were combined to statistically determine whether two key process variables, ovens temperature and conveyors speed, had an impact on the number of defects produced, as well as to define their optimum values needed to reduce/eliminate the defe...

A framework for the integration of Green and Lean Six Sigma for superior sustainability performance

Evidence suggests that Lean, Six Sigma and Green approaches make a positive contribution to the economic, social and environmental (i.e. sustainability) performance of organisations. However, evidence also suggests that organisations have found their integration and implementation challenging. The purpose of this research is therefore to present a framework that methodically guides companies through a five stages and sixteen steps process to effectively integrate and implement the Green, Lean and Six Sigma approaches to improve their sustainability performance. To achieve this, a critical review of the existing literature in the subject area was conducted to build a research gap, and subsequently develop the methodological framework proposed. The paper presents the results from the application of the proposed framework in four organisations with different sizes and operating in a diverse range of industries. The results showed that the integration of Lean Six Sigma and Green helped the organisations to averagely reduce their resources consumption from 20 to 40% and minimise the cost of energy and mass streams by 7–12%. The application of the framework should be gradual, the companies should assess their weaknesses and strengths, set priorities, and identify goals for successful implementation. This paper is one of the very first researches that presents a framework to integrate Green and Lean Six Sigma at a factory level, and hence offers the potential to be expanded to multiple factories or even supply chains.

The development of a lean park homes production process using process flow and simulation methods

Purpose – Continuous process flow is a prerequisite of lean systems as it helps to reduce throughput times, improve quality, minimize operational costs, and shorten delivery times. The purpose of this paper is to empirically demonstrate the application of a methodology that combines a time‐based study, discrete‐event simulation and the trial and error method to enable a leaner process through more efficient line balancing and more effective flow for a park homes production process. This method is replicable across other contexts and industry settings.Design/methodology/approach – The paper reviews the UK park homes production industry and, specifically, a major factory that builds these homes. It compares the factory method to traditional on‐site construction methods. An empirical study of production times was carried out to collect data in order to analyse the current workload distribution and the process flow performance of the park homes production process. Finally, seven discrete‐event simulation mode...

Lean and green in the transport and logistics sector – a case study of simultaneous deployment

Abstract The transport and logistics sector is of vital importance for the stimulation of trade and hence the economic development of nations. However, over the last few years, this sector has taken central stage in the green agenda due to the negative environmental effects derived from its operations. Several disciplines including operations research and sub-areas of supply chain management such as green supply chains, green logistics and reverse logistics have tried to address this problem. However, despite the work undertaken through these disciplines, theoretical or empirical research into the sequential or simultaneous deployment of the lean and green paradigms, particularly, in the road transport and logistics sector is limited. This paper presents a case study where both paradigms have been combined to improve the transport operations of a world leader logistics organisation in the metropolitan area of Monterrey, Mexico. To do this, a systematic methodology and a novel tool called Sustainable Transportation Value Stream Map (STVSM) were proposed. The results obtained from the case study indicate that the concurrent deployment of the green and lean paradigms through such methodology and the STVSM tool is an effective approach to improve both operational efficiency and environmental performance of road transport operations. The paper can be used as a guiding reference for transport and logistics organisations to undertake improvement projects similar to the one presented in this paper. Additionally, this research also intends to stimulate scholarly research into the application of lean and green paradigms in the transport and logistics sector to expand the limited research pursued in this area.

Developing green supply chain management taxonomy-based decision support system

The aim of this paper is to develop a comprehensive taxonomy of green supply chain management (GSCM) practices and develop a structural equation modelling-driven decision support system following GSCM taxonomy for managers to provide better understanding of the complex relationship between the external and internal factors and GSCM operational practices. Typology and/or taxonomy play a key role in the development of social science theories. The current taxonomies focus on a single or limited component of the supply chain. Furthermore, they have not been tested using different sample compositions and contexts, yet replication is a prerequisite for developing robust concepts and theories. In this paper, we empirically replicate one such taxonomy extending the original study by (a) developing broad (containing the key components of supply chain) taxonomy; (b) broadening the sample by including a wider range of sectors and organisational size; and (c) broadening the geographic scope of the previous studies. Moreover, we include both objective measures and subjective attitudinal measurements. We use a robust two-stage cluster analysis to develop our GSCM taxonomy. The main finding validates the taxonomy previously proposed and identifies size, attitude and level of environmental risk and impact as key mediators between internal drivers, external drivers and GSCM operational practices.