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Handbook of Research on Design and Management of Lean Production Systems

Book Description

In a production environment, batch size is proportional to cost and productivity. Innovative technologies have emerged in lean manufacturing as a way to include a number of elements that emphasizes waste reduction, value enhancement, and high quality results. Handbook of Research on Design and Management of Lean Production Systems explores the recent advancements in the areas of lean production, management, and the system and layout design for manufacturing environments. It also captures the building blocks of lean transformation on a shop floor level. Providing further understanding and ideas of this subject area, this book is an essential reference source for academic researchers as well as managers and practitioners of organizations.

Table of Contents

  1. Cover
  2. Title Page
  3. Copyright Page
  4. Book Series
  5. Editorial Advisory Board and List of Reviewers
    1. Editorial Advisory Board
    2. List of Reviewers
  6. Preface
    1. ABOUT THE SUBJECT
    2. ORGANIZATION OF THE BOOK
    3. Target Audience
  7. Acknowledgment
  8. Section 1: Introduction to Development of Manufacturing Paradigms
    1. Chapter 1: The Evolution of Manufacturing Systems
      1. ABSTRACT
      2. INTRODUCTION
      3. METHODOLOGY OF THIS REVIEW CHAPTER
      4. STRUCTURE OF THE CHAPTER
      5. EVOLUTION OF MANUFACTURING PARADIGMS
      6. CONCLUSION AND FUTURE TRENDS
  9. Section 2: Modeling and Designing of Lean Production System
    1. Chapter 2: Mathematical Modeling and Genetic Algorithms for Product Sequencing in a Cellular System
      1. ABSTRACT
      2. INTRODUCTION
      3. BACKGROUND
      4. PROBLEM STATEMENT
      5. PROPOSED SOLUTION APPROACHES
      6. EXPERIMENTS AND RESULTS
      7. FUTURE WORK AND CONCLUDING REMARKS
    2. Chapter 3: Maximization of Delivery-Based Customer Satisfaction Considering Customer-Job Relationships in a Cellular Manufacturing Environment
      1. ABSTRACT
      2. INTRODUCTION
      3. BACKGROUND
      4. PROBLEM STATEMENT
      5. THE PROPOSED METHODOLOGY
      6. EXPERIMENTATION AND RESULTS
      7. CONCLUSION AND FUTURE RESEARCH DIRECTIONS
    3. Chapter 4: On Designing Robust Kanban Production Control Strategies in Multiproduct Manufacturing Environments
      1. ABSTRACT
      2. INTRODUCTION
      3. BACKGROUND
      4. METHODS TO COMPARE DIFFERENT PRODUCTION CONTROL STRATEGIES
      5. A HYBRID KANBAN CARD ALLOCATION POLICY FOR MULTI-PRODUCT ENVIRONMENTS WITH HIGH DEMAND VARIABILITY
      6. SOLUTIONS AND RECOMMENDATIONS
      7. FUTURE RESEARCH DIRECTIONS
      8. CONCLUSION
    4. Chapter 5: Lean Manufacturing System Design Based on Computer Simulation
      1. ABSTRACT
      2. INTRODUCTION
      3. PROBLEM BACKGROUND
      4. DESCRIPTION OF THE PRODUCTION LINE FOR THE MANUFACTURE OF ELECTRONIC CONTROL UNITS FOR AUTOMOBILE MOTORS
      5. CONSTRUCTION OF THE MODEL IN THE WITNESS ENVIRONMENT
      6. SIMULATION EXPERIMENTS AND RESULTS
      7. CONCLUSION
    5. Chapter 6: Modeling and Control of Production Task Flows using High-Level Activity-Based Petri Nets
      1. ABSTRACT
      2. INTRODUCTION
      3. BACKGROUND
      4. HIERARCHICAL APPROACH FOR PRODUCTION SYSTEMS
      5. MODELING OF PRODUCTION TASKS USING EXTENDED PETRI NETS
      6. REPRESENTATION OF PRODUCTIVE ACTIVITIES AND DISTRIBUTIONS USING HIGH-LEVEL PETRI NETS
      7. EXAMPLE OF HIERARCHICAL PETRI NET BASED CONTROL SYSTEM DESIGN
      8. CONCLUSION
  10. Section 3: Good Practices of Implementation of Lean Manufacturing Principles
    1. Chapter 7: Cell Design for Transforming the Job Shop Production Process to Lean
      1. ABSTRACT
      2. INTRODUCTION
      3. RESEARCH BACKGROUND
      4. CONDITIONS FOR TRANSFORMATION FROM JOB SHOP PRODUCTION TO LEAN
      5. CASE STUDY
      6. CONCLUSION AND FUTURE RESEARCH DIRECTIONS
    2. Chapter 8: Implementing Lean in Engineer-to-Order Manufacturing
      1. ABSTRACT
      2. INTRODUCTION
      3. BACKGROUND AND LITERATURE REVIEW
      4. IMPLEMENTING LEAN IN ENGINEER-TO-ORDER MANUFACTURING
      5. FUTURE RESEARCH
      6. CONCLUSION
    3. Chapter 9: A Management System for Sustainable Lean Implementation
      1. ABSTRACT
      2. INTRODUCTION
      3. BACKGROUND
      4. TOWARDS A MANAGEMENT SYSTEM FOR LEAN
      5. FUTURE RESEARCH DIRECTIONS
    4. Chapter 10: Integration of MRP Logic and Kanban Shopfloor Control
      1. ABSTRACT
      2. INTRODUCTION
      3. BACKGROUND
      4. MRP
      5. KANBAN
      6. MRP VS. KANBAN
      7. INTEGRATION OF MRP AND KANBAN
      8. ILLUSTRATIVE CASE STUDY: AGRICO
      9. FUTURE RESEARCH DIRECTIONS
      10. CONCLUSION
    5. Chapter 11: Lean Transformation in Small and Medium Enterprises
      1. ABSTRACT
      2. INTRODUCTION
      3. LITERATURE REVIEW
      4. RESEARCH METHODOLOGY
      5. LEAN TRANSFORMATION PROCESS IN SMES: A TOOL BASED ANALYSIS
      6. ENABLING AND CONSTRAINTS IN LEAN TRANSFORMATION PROCESSES
      7. CONCLUSION
    6. Chapter 12: Is Lean Supply an Option for SMEs in the Automotive Industry
      1. ABSTRACT
      2. BACKGROUND
      3. LITERATURE REVIEW
      4. METHODOLOGY
      5. RESULTS
      6. DISCUSSION
      7. CONCLUSION
  11. Section 4: Operations and Supply Chain Management in the Lean Manufacturing Systems and Related Issues
    1. Chapter 13: A Corporate Perspective on Global Management and Development of Lean Production Systems
      1. ABSTRACT
      2. INTRODUCTION
      3. BACKGROUND
      4. THE PRACTICAL ISSUE OF LEAN IMPLEMENTATION: THE GYPROC CASE
      5. DISCUSSIONS
      6. FUTURE RESEARCH DIRECTIONS
      7. CONCLUSION
    2. Chapter 14: Auditing for Measuring the Extent of Lean Implementation
      1. ABSTRACT
      2. INTRODUCTION
      3. LITERATURE REVIEW ON LEAN ASSESSMENT AND LEAN AUDIT
      4. CONCEPTUAL FEATURES OF LEAN AUDIT
      5. DETAILS ABOUT THE AUDIT
      6. RESULTS AND DISCUSSIONS
      7. CONCLUSION
    3. Chapter 15: Lean Management and Supply Chain Management
      1. ABSTRACT
      2. INTRODUCTION
      3. METHODOLOGY
      4. RESULTS
      5. DISCUSSION, GAPS, AND FUTURE RESEARCH LINES
      6. CONCLUSION AND IMPLICATIONS
    4. Chapter 16: Dynamic Supply Chain Management for Lean Manufacturing
      1. ABSTRACT
      2. INTRODUCTION
      3. BACKGROUND
      4. TWO-LAYERED DYNAMIC SUPPLY CHAIN MODEL
      5. THREE-LAYERED MODEL FOR MULTI-LAYERED DYNAMIC SUPPLY CHAIN
      6. ORDER SELECTION METHOD
      7. COMPUTATIONAL EXPERIMENTS
      8. CONCLUSION
    5. Chapter 17: The Role of Lean Production on Organizational Performance
      1. ABSTRACT
      2. INTRODUCTION
      3. BACKGROUND
      4. MAIN FOCUS OF THE CHAPTER
      5. JUST IN TIME
      6. TOTAL PRODUCTIVE MAINTENANCE
      7. TOTAL QUALITY MANAGEMENT
      8. CELLULAR MANUFACTURING
      9. HUMAN RESOURCE MANAGEMENT
      10. ORGANIZATIONAL PERFORMANCE
      11. THE IMPACT OF LEAN PRODUCTION ON ORGANIZATIONAL PERFORMANCE
      12. SOLUTIONS AND RECOMMENDATIONS
      13. FUTURE RESEARCH DIRECTIONS
      14. CONCLUSION
    6. Chapter 18: Blending Green with Lean - Incorporating Best-of-the-Breed Practices to Formulate an Optimum Global Supply Chain Management Framework
      1. ABSTRACT
      2. INTRODUCTION
      3. BACKGROUND
      4. IMPACT ANALYSIS OF EXISTING SUPPLY CHAIN PRACTICES IN PROPOSITION TO ENVIRONMENTAL NECESSITY AND BUSINESS SUSTAINABILITY: ISSUES, CONTROVERSIES, AND PROBLEMS
      5. COMPREHENSIVE LEAN-GREEN SUPPLY CHAIN MANAGEMENT PRACTICES: PERFORMANCE FRAMEWORK
      6. DISCUSSION
      7. LIMITATIONS AND FUTURE RESEARCH
      8. CONCLUSION
  12. Compilation of References
  13. About the Contributors