Classification scheme for lean manufacturing tools

S. J. Pavnaskar · John K. Gershenson · Anil B. Jambekar

466 citations0/0 files storedInternational Journal of Production Research

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Quality and Supply Management Management and Optimization Techniques Digital Transformation in Industry

Abstract

For the past few years almost every manufacturing industry has been trying to get 'lean'. A headlong rush to become lean also resulted in many misapplications of existing lean manufacturing tools often due to inadequate understanding of the purpose of tools. While tool descriptions abound, there is no way systematically to link a manufacturing organization to its problems and to the possible tools to eliminate these problems. The main purpose of this paper is to propose a classification scheme to serve as a link between manufacturing waste problems and lean manufacturing tools. A manufacturing organization can then match its manufacturing wastes with the appropriate lean manufacturing tools. The classification of existing knowledge is often the first step in moving from a practice to a science. This classification scheme systematically organizes lean manufacturing tools and metrics according to their level of abstraction, appropriate location of application of the tool in the organization, whether it addresses management waste or activity waste, the type of resource waste it addresses, and whether it identifies waste, measures waste, eliminates waste, or a combination of the three. We have organized 101 lean manufacturing tools and metrics using this classification scheme. We have also described some common manufacturing problems using this classification scheme and shown the problem-tool connection through examples. The classification scheme is not intended as a decision-making tool, i.e. it does not decide if something is a waste. However, the proposed scheme does an excellent job of classifying all well-known lean manufacturing tools and metrics and suggests lean manufacturing tools and metrics that will help to address manufacturing problems. This classification scheme will assist companies trying to become lean and can serve as a foundation for research into the science of lean.

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References

1992The machine that changed the world 1983Japanese Manufacturing Techniques: Nine Hidden Lessons in Simplicity

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2014The impact of lean methods and tools on the operational performance of manufacturing organisations 2012Four decades of lean: a systematic literature review 2010The integration of Six Sigma and lean management 2005Application of value stream mapping for lean operations and cycle time reduction: an Indian case study 2017A Systematic Literature Review on Recent Lean Research: State‐of‐the‐art and Future Directions 2013Implementing lean production systems: research areas and opportunities for future studies 2013A methodology for effective implementation of lean strategies and its performance evaluation in manufacturing organizations 2008Implementing 5S within a Japanese context: an integrated management system

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