Conceptual Analysis Of Lean Principles And Tools In Manufacturing Industries
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Date
2022-07-24
Authors
Osman, Muhamad Nazmi
Journal Title
Journal ISSN
Volume Title
Publisher
Universiti Sains Malaysia
Abstract
Today, the ideas and techniques of Lean Manufacturing (LM) are utilised extensively
by companies all over the world to reduce waste and make processes more effective.
The Lean methodology is widely acknowledged as one of the most effective methods
for boosting an organization's productivity and, by extension, its level of
competitiveness. The purpose of this paper is to find the implementation status of Lean
principles and tools across Malaysian manufacturing organizations through the
empirical survey methodology. This paper provides a discussion of lean ideas and
techniques that have been implemented in the Malaysian industries involved in
manufacturing. The survey questionnaire was developed based upon literature review
conducted on LM and also considered experts suggestion in the field of LM. The survey
questionnaire was sent to 120 respondents that are currently working in manufacturing
industries located in Malaysia. The selected respondents were production managers,
quality managers, sales managers, maintenance managers, and also engineering
students. The empirical survey collected 107 filled survey questionnaires from
Malaysian manufacturing industries. This study makes a contribution by highlighting
the relationship of applying lean tools to lean principles within the context of the
Malaysian manufacturing sector. study. In lean manufacturing principles, five primary
rules are used to measure leanness. These principles include value, value stream, flow,
pull, and perfection. In addition, the analysis illustrates how the five different lean
principles connect to the lean tools present in the production system. However, for an
organization to successfully implement lean, it must choose the best tools for
production. There are many lean tools, such as Value Stream Mapping (VSM), Cellular
Manufacturing (CM), U-line System, Line Balancing, Inventory Control, Single Minute
Exchange of Dies (SMED), Pull System, and Kanban. Thus, it is quite hard to select
the right tool to implement in their company and achieve each principle's goals. In this
paper, an effort has been made to determine which tools can be used for each lean
principle by collecting a survey and seeing the significance of the company's
preparation for implementing the lean manufacturing system.