Lean Manufacturing: Fundamentals, Tools, Approaches, and Industry 4.0 Integration

133 Pages·2022·4.019 MB·English

by  S. Vinodh

Lean Manufacturing
Lean Manufacturing concepts are being applied to a variety of industries.
These concepts ensure streamlined processes through a systematic analysis of
wastes and elimination, while enhancing value. This book offers fundamen-
tals, theoretical concepts, case studies, and examples, along with insights for
lean integration in Industry 4.0.
The book offers a comprehensive coverage of topics in Lean Manufacturing
which includes lean elements and tools, performance measures, project selec-
tion, integration, along with other related strategies. It ensures a balance
between theory and practice of Lean Manufacturing by including the imple-
mentation aspects of lean tools. The book will explore insights for Industry 4.0
related to lean concepts and provide details on how they relate. Illustrations
and examples depicting OEE ( Overall Equipment Effectiveness) analysis and
value stream map analysis are included. The book also provides case studies
on Lean Manufacturing covering value stream mapping, project selection, and
performance measurement.
Lean Manufacturing: Fundamentals, Tools, Approaches, and Industry
4.0 Integration can be used as a reference for academic researchers and
industry practitioners. Undergraduate and postgraduate students can use it for
a course on Lean Manufacturing. Doctoral students can also refer to it for
advanced concepts, and industry practitioners can use it for practical insights.

Lean Manufacturing
Fundamentals, Tools, Approaches, and
Industry 4.0 Integration
S. Vinodh
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MathWorks does not warrant the accuracy of the text or exercises in this book. This book’s
use or discussion of MATLAB® software or related products does not constitute endorse-
ment or sponsorship by The MathWorks of a particular pedagogical approach or particular
use of the MATLAB® software.
First edition published 2023
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ISBN: 9 78-1 -0 32-0 4045-5 (h bk)
ISBN: 9 78-1 -0 32-0 4046-2 (p bk)
ISBN: 978- 1- 003- 19033-2 ( ebk)
DOI: 10.1201/9 781003190332
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This book is dedicated to my Aunt, Professors, Teachers, Parents, Wife,
Son, Students, Friends, and Well-wishers.

Contents
Preface xi
Acknowledgments xv
Author Biography xvii
1 Introduction 1
1.1 Manufacturing Systems Transition 1
1.2 Origin of Lean Manufacturing 2
1.3 Definition and Concepts of Lean Manufacturing 2
1.4 Comparison of Mass and Lean Manufacturing 4
1.5 Summary 5
2 Lean Principles and Waste Categories 7
2.1 Lean Principles 7
2.2 Muda, Muri, and Mura 8
2.3 Waste and Waste Categories 8
2.4 Waste Analysis 10
2.5 Kaizen 10
2.6 Summary 11
3 Elements of Lean Manufacturing 13
3.1 Overview on Elements 13
3.2 Discussion on Elements ( Value Stream and Value Flow) 13
3.3 Activity Categorization in Value Stream 14
3.4 Push and Pull Production 15
3.5 Stability, Standardized Work, and SOPs for Lean System 16
3.6 Visual Management and Single-Piece Flow Concepts 16
3.7 Summary 17
4 Basic Lean Tools ( 5S and TPM) 19
4.1 5S Lean Tool 19
4.2 5S Implementation 22
4.3 Total Productive Maintenance – Overview and Pillars 24
4.4 OEE Analysis 27
4.5 TPM Implementation 28
4.6 Summary 30
vii
viii Contents
5 Basic Lean Tools ( VSM and Workcell) 33
5.1 Overview on Process Mapping and Value Stream
Mapping (VSM) 33
5.2 VSM Terminologies and Data Types ( Observation/
Measurement, Computation Data) 36
5.3 Construction Steps of Value Stream Maps 37
5.4 VSM Illustration and Case Study 37
5.5 Variants of VSM ( Advanced Models of VSM) 39
5.6 Workcell 42
5.7 Case on Lean Tools Selection 43
5.8 Summary 45
6 Supporting Lean Tools and Concepts 51
6.1 Scope of Supporting Tools 51
6.2 Description of Core Supporting Tools ( Poka Yoke,
Kanban, Autonomation, Visual Communication,
and SMED) 51
6.3 Optimized Production Technology, Leveled Production,
and Enterprise Resource Planning 54
6.4 Summary 56
7 Project Selection and Training for Lean Implementation 59
7.1 Importance of Project Selection 59
7.2 Project Selection for Lean Implementation 59
7.3 Training and Implementation for Lean 67
7.4 Lean Implementation Levels 68
7.5 Summary 68
8 Lean Performance Measurement 71
8.1 Lean Performance Measures 71
8.2 Assessment Approaches 73
8.3 Case Study on Leanness Assessment 75
8.4 Summary 89
9 Lean Integration with Other Strategies 91
9.1 Lean Six Sigma 91
9.2 Lean and Agile Manufacturing 92
9.3 Lean Sustainability 93
9.4 Summary 94
Contents ix
10 Lean Integration with Industry 4.0 95
10.1 Need and Scope of Integration 95
10.2 Insights on Lean and Industry 4.0
Integration 96
10.3 Analysis of Workforce Attributes for Lean
and Industry 4.0 97
10.4 Summary 98
11 Research Issues in Lean Manufacturing 105
11.1 Application Domains in Lean Manufacturing 105
11.2 Research Avenues in Lean Manufacturing 105
11.3 Summary 108
Index 111