A novel tool-input-process-output (TIPO) framework for upgrading to lean 4.0

Authors

DOI:

https://doi.org/10.4995/ijpme.2024.19723

Keywords:

Lean Manufacturing, Industry 4.0, Lean 4.0, TIPO, JIT, Jidoka, Heijunka

Abstract

For more than four decades, Lean Manufacturing (LM) has delivered in terms of waste reduction, productivity and sustainability for the benefit of manufacturers, customers and society at large. In the present era of Industry 4.0 (I4.0), the integration of physical and digital systems is providing huge scope for enhancing the performances of conventional lean tools and practices. Although recent literature has emphasized the integration of lean and Industry 4.0 as Lean 4.0, the mode of integration and basis for selecting technologies need to be explored more. The present paper aims to address this gap and presents a novel Tool-Input-Process-Output (TIPO) approach in which ‘Inputs’ required for the implementation of conventional lean tools are identified and mapped with core characteristics of I4.0 technologies to develop the ‘Process’ for the integration. Exemplified on three prominent lean tools; Just-In-Time (JIT), Jidoka and Heijunka  to illustrate the proposed framework.  

Downloads

Download data is not yet available.

References

Agostinho, V., & Baldo, C.R. (2020). Assessment of the impact of Industry 4.0 on the skills of Lean professionals. Procedia CIRP, 96, 225-229. https://doi.org/10.1016/j.procir.2021.01.079

Bittencourt, V.L., Alves, A.C., & Leão, C.P. (2019). Lean Thinking contributions for Industry 4.0: A systematic literature review. IFAC-PapersOnLine, 52(13), 904-909. https://doi.org/10.1016/j.ifacol.2019.11.310

Bittencourt, V.L., Alves, A.C., & Leão, C.P. (2021). Industry 4.0 triggered by Lean Thinking: insights from a systematic literature review. International Journal of Production Research, 59(5), 1496-1510. https://doi.org/10.1080/00207543.2020.1832274

Boutbagha, M., Laila, A. (2022). Production Leveling or Heijunka: A Bibliometric Study. Proceedings of 2022 IEEE 3rd International Conference on Electronics, Control, Optimization and Computer Science (ICECOCS). Morocco. https://doi.org/10.1109/ICECOCS55148.2022.9982975

Buer, S.V., Semini, M., Strandhagen, J.O., & Sgarbossa, F. (2021). The complementary effect of lean manufacturing and digitalisation on operational performance. International Journal of Production Research, 59(7), 1976-1992. https://doi.org/10.1080/00207543.2020.1790684

Buer, S.V., Strandhagen, J.O., & Chan, F.T.S. (2018). The link between industry 4.0 and lean manufacturing: Mapping current research and establishing a research agenda. International Journal of Production Research, 56(8), 2924-2940. https://doi.org/10.1080/00207543.2018.1442945

Calış Duman, M., & Akdemir, B. (2021). A study to determine the effects of industry 4.0 technology components on organizational performance. Technological Forecasting and Social Change, 167. https://doi.org/10.1016/j.techfore.2021.120615

Carvalho, C.P., Gonçalves, L.W.N., & Silva, M.B. (2019). Value stream mapping as a lean manufacturing tool: A new account approach for cost saving in a textile company. International Journal of Production Management and Engineering, 6(2), 1-12. https://doi.org/10.4995/ijpme.2019.8607

Chiarini, A., Belvedere, V., & Grando, A. (2020). Industry 4.0 strategies and technological developments. An exploratory research from Italian manufacturing companies. Production Planning and Control, 31(16), 1385-1398. https://doi.org/10.1080/09537287.2019.1710304

Ciano, M.P., Dallasega, P., Orzes, G., & Rossi, T. (2021). One-to-one relationships between Industry 4.0 technologies and Lean Production techniques: a multiple case study. International Journal of Production Research, 59(5), 1386-1410. https://doi.org/10.1080/00207543.2020.1821119

Cifone, F.D., Hoberg, K., Holweg, M., & Staudacher, A.P. (2021). 'Lean 4.0': How can digital technologies support lean practices?. International Journal of Production Economics, 241. https://doi.org/10.1016/j.ijpe.2021.108258

Dahmani, N., Benhida, K., Belhadi, A., Kamble, S., Elfezazi, S., Jauhar, S.K. (2021). Smart circular product design strategies towards eco-effective production systems: a lean eco-design industry 4.0 framework. Journal of Cleaner Production, 320, 128847. https://doi.org/10.1016/j.jclepro.2021.128847

Deuse, J., Dombrowski, U., Nöhring, F., Mazarov, J., & Dix, Y. (2020). Systematic Combination of Lean Management with Digitalisation to Improve Production Systems on the Example of Jidoka 4.0. International Journal of Engineering Business Management, 12(3),1-9. https://doi.org/10.1177/18479790221147864

Drew, J., McCallum, B., & Roggenhofer, S. (2004). Journey to Lean: Making Operational Change Stick (1st ed.). Palgrave Macmillan London. https://doi.org/10.1057/9781403948410

El Faydy, N., El Abbadi, L. (2023). Interpretive structural modelling of critical success factor for lean product lifecycle management in industry 4.0. International Journal of Production Management and Engineering, 11(1), 65-72. https://doi.org/10.4995/ijpme.2023.18840

Gil-Vilda, F., Yagüe-Fabra, J.A., & Sunyer, A. (2021). From lean production to lean 4.0: A systematic literature review with a historical perspective. Applied Sciences, 11(21). https://doi.org/10.3390/app112110318

Gunasekaran, A., & Lyu, J. (1997). Implementation of just-in-time in a small company: A case study. Production Planning and Control, 8(4), 406-412. https://doi.org/10.1080/095372897235217

Hofmann, E., & Rüsch, M. (2017). Industry 4.0 and the current status as well as future prospects on logistics. Computers in Industry,89,23-34. https://doi.org/10.1016/j.compind.2017.04.002

Hopp, W.J., & Spearman, M.S. (2021). The lenses of lean: Visioning the science and practice of efficiency. Journal of Operations Management, 67(5), 610-626. https://doi.org/10.1002/joom.1115

Jastia, N.V.K., & Kodali, R. (2015). Lean production: Literature review and trends. International Journal of Production Research, 53(3), 867-885. https://doi.org/10.1080/00207543.2014.937508

Jina, J., Bhattacharya, A.K., & Walton, A.D. (1997). "Applying lean principles for high product variety and low volumes: some issues and propositions. Logistics Information Management, 10(1), 5-13. https://doi.org/10.1108/09576059710159655

Kagermann H. (2013). Recommendations for implementing the strategic initiative INDUSTRIE 4.0. April 2013 Securing the future of German manufacturing industry Final report of the Industrie 4.0 Working Group.

Kamble, S., Gunasekaran, A., & Dhone, N.C. (2020). Industry 4.0 and lean manufacturing practices for sustainable organisational performance in Indian manufacturing companies" International Journal of Production Research, 58(5), 1319-1337. https://doi.org/10.1080/00207543.2019.1630772

Karim, A., & Arif-Uz-Zaman, K. (2013). A methodology for effective implementation of lean strategies and its performance evaluation in manufacturing organizations. Business Process Management Journal, 19(1), 169-196. https://doi.org/10.1108/14637151311294912

Kipper, L.M., Furstenau, L.B., Hoppe, D., Frozza, R., & Iepsen, S. (2020). Scopus scientific mapping production in industry 4.0 (2011-2018): a bibliometric analysis. International Journal of Production Research, 58(6), 1605-1627. https://doi.org/10.1080/00207543.2019.1671625

Kolberg, D., & Zühlke, D. (2015). Lean Automation enabled by Industry 4.0 Technologies. IFAC-PapersOnLine, 28(3), 1870-1875. https://doi.org/10.1016/j.ifacol.2015.06.359

Kolberg, D., Knobloch, J., & Zühlke, D. (2017). Towards a lean automation interface for workstations, International Journal of Production Research, 55(10), 2845-2856. https://doi.org/10.1080/00207543.2016.1223384

Krafcik, J.F. (1988). Triumph Of The Lean Production System. Sloan Management Review, 30(1), 41-52.

Marodin, G., Chiappetta Jabbour, C.J., Godinho Filho, M., & Tortorella, G.L. (2022). Lean production, information and communication technologies and operational performance. Total Quality Management and Business Excellence, 32(1), 183-200. https://doi.org/10.1080/14783363.2022.2035214

Mayr, A., Weigelt, M., Kühl, A., Grimm, S., Erll, A., Potzel, M., & Franke, J. (2018). Lean 4.0-A conceptual conjunction of lean management and Industry 4.0. Procedia CIRP, 72, 622-628. https://doi.org/10.1016/j.procir.2018.03.292

Mittal, S., Khan, M.A., Romero, D., & Wuest, T. (2018). A critical review of smart manufacturing & Industry 4.0 maturity models: Implications for small and medium-sized enterprises (SMEs). Journal of Manufacturing Systems,49(2), 194-214. https://doi.org/10.1016/j.jmsy.2018.10.005

Monden, Y. (1983). Toyota Production System. Norcross: Industrial Engineering and Management Press.

Nai Yeen Gavin Lai, Kok Hoong Wong, Dunant Halim, Jiawa Lu, & Hooi Siang Kang. (2019). Industry 4.0 Enhanced Lean Manufacturing. Proceedings of 8th International Conference on Industrial Technology and Management: ICITM 2019, 206-211. https://doi.org/10.1109/ICITM.2019.8710669

Najwa, E., Bertrand, R., Yassine, M., Fernandes, G., Abdeen, M., & Souad, S. (2021). Lean 4.0 tools and technologies to improve companies' maturity level: The COVID-19 context. Procedia Computer Science, 196, 207-216. https://doi.org/10.1016/j.procs.2021.12.007

Ohno, T. (1988). Toyota production system: beyond large-scale production. Productivity Press.Pagliosa, M., Tortorella, G., & Ferreira, J.C.E. (2021). Industry 4.0 and Lean Manufacturing: A systematic literature review and future research directions. Journal of Manufacturing Technology Management, 32(3), 543-569. https://doi.org/10.1108/JMTM-12-2018-0446

Pereira, A., Carvalho, J.D., Anabela, A. and Pedro A. (2019). How Industry 4.0 Can Enhance Lean Practices. FME Transactions, 47(4), 810-822. https://doi.org/10.5937/fmet1904810P

Pereira, A.C., & Romero, F. (2017). A review of the meanings and the implications of the Industry 4.0 concept. Procedia Manufacturing,13, 1206-1214. https://doi.org/10.1016/j.promfg.2017.09.032

Peter, H., Tortorella, G.L., Antony, J., & Romero, D. (2022). Lean Industry 4.0:Past, present, Future. Quality Management Journal. 30 (1), 64-68. https://doi.org/10.1080/10686967.2022.2144786

Powell, D., Romero, D., Gaiardelli, P., Cimini, C., & Cavalieri, S. (2018). Towards Digital Lean Cyber-Physical Production Systems: Industry 4.0 Technologies as Enablers of Leaner Production. APMS - Production Management for Data-Driven, Intelligent, Collaborative, and Sustainable Manufacturing, 353-362. https://doi.org/10.1007/978-3-319-99707-0_44

Prinz, C., Niklas, K. and Bernd, K. (2018). Lean Meets Industrie 4.0 - a Practical Approachto Interlink the Method World and Cyber-Physical World. Procedia Manufacturing23, 21-26. https://doi.org/10.1016/j.promfg.2018.03.155

Romero, D., Gaiardelli, P., Powell, D., Wuest, T., & Thürer, M. (2018). Digital lean cyber-physical production systems: The emergence of digital lean manufacturing and the significance of digital waste. IFIP Advances in Information and Communication Technology, 535, 11-20. https://doi.org/10.1007/978-3-319-99704-9_2

Romero, David, Gaiardelli, Paolo, Powell, Daryl, Wuest, Thorsten, Thürer, Matthias, (2019). Rethinking jidoka systems under automation & learning perspectives in thedigital lean manufacturing world. IFAC-PapersOnLine,52(13), 899-903. https://doi.org/10.1016/j.ifacol.2019.11.309

Rosin, F., Forget, P., Lamouri, S., & Pellerin, R. (2020). Impacts of Industry 4.0 technologies on Lean principles. International Journal of Production Research, 58(6), 1644-1661. https://doi.org/10.1080/00207543.2019.1672902

Rossi, A.H.G.; Marcondes, G.B.; Pontes, J.; Leitão, P.; Treinta, F.T.; De Resende, L.M.M.; Mosconi, E.; Yoshino, R.T. (2022). Lean Tools in the Context of Industry 4.0: Literature Review Implementation and Trends. Sustainability, 14, 12295. https://doi.org/10.3390/su141912295

Rossini, M., Costa, F., Tortorella, G.L., & Portioli-Staudacher, A. (2019). The interrelation between Industry 4.0 and lean production: an empirical study on European manufacturers. International Journal of Advanced Manufacturing Technology, 102(9-12), 3963-3976. https://doi.org/10.1007/s00170-019-03441-7

Sanders, A., Elangeswaran, C., & Wulfsberg, J. (2016). Industry 4.0 implies lean manufacturing: Research activities in industry 4.0 function as enablers for lean manufacturing. Journal of Industrial Engineering and Management, 9(3): 811-833. https://doi.org/10.3926/jiem.1940

Santos, B.P.; Enrique, D.V.; Maciel, V.B.P.; Lima, T.M.; Charrua-Santos, F.; Walczak, R. (2021). The synergic relationship between industry 4.0 and lean management: Best practices from the literature. Management and Production Engineering Review, 12, 94-107.

Saraswat, P., Agrawal, R., & Meena, M.L. (2021). An Analysis of Critical Success Factors Using Analytical Hierarchy Process for Implementation of Lean with Industry 4.0 in SMEs.. In Recent Advances in Smart Manufacturing and Materials. Lecture Notes in Mechanical Engineering. Springer, Singapore. 255-262. https://doi.org/10.1007/978-981-16-3033-0_24

Sartal, A., Llach, J., & León-Mateos, F. (2022). Do technologies really affect that much? exploring the potential of several industry 4.0 technologies in today's lean manufacturing shop floors. Operational Research, 22(5), 6075-6106. https://doi.org/10.1007/s12351-022-00732-y

Satoglu, S., Ustundag, A., Cevikcan, E., Durmusoglu, M. (2018). Lean transformation integrated with Industry 4.0 implementation methodology. Industrial Engineering in the Industry 4.0 Era. Springer, Cham, pp. 97-107. https://doi.org/10.1007/978-3-319-71225-3_9

Schumacher, S., Bildstein, A., & Bauernhansl, T. (2020). The impact of the digital transformation on lean production systems. Procedia CIRP, 93, 783-788. https://doi.org/10.1016/j.procir.2020.03.066

Sihle, M., & Sambil M. (2018). The Impact of Just-in-Time (JIT) in Inventory Management System and the Supplier Overall Performance of South African's Bed Mattress Manufacturing Companies. International Conference on Industrial Engineering and Operations ManagementAt: Pretoria / Johannesburg, South Africa.

Spenhoff, P., Johan C., & Wortmann & Marco Semini (2022). EPEC 4.0: an Industry 4.0-supported lean production control concept for the semi-process industry. Production Planning & Control, 33(14), 1337-1354. https://doi.org/10.1080/09537287.2020.1864496

Taghavi, V., & Beauregard, Y. (2020). The Relationship between Lean and Industry 4.0: Literature Review. 5th North American Conference on Industrial Engineering and Operations Management in Detroit, Michigan, USA during August 10-14, 2020.

Tampubolon, S., & Purba, H.H. (2021). Lean Six Sigma Implementation, A Systematic Literature Review. International Journal of Production Management and Engineering, 9(2), 125-139. https://doi.org/10.4995/ijpme.2021.14561

Tortorella, G.L., & Fettermann, D. (2018). Implementation of industry 4.0 and lean production in brazilian manufacturing companies. International Journal of Production Research, 56(8),2975-2987. https://doi.org/10.1080/00207543.2017.1391420

Tortorella, G., Sawhney, R., Jurburg, D., de Paula, I.C., Tlapa, D., & Thurer, M. (2021). Towards the proposition of a Lean Automation framework: Integrating Industry 4.0 into Lean Production. Journal of Manufacturing Technology Management,32(3), 593-620. https://doi.org/10.1108/JMTM-01-2019-0032

Valamede, L.S., & Akkari, A.C.S. (2020). Lean 4.0: A new holistic approach for the integration of lean manufacturing tools and digital technologies. International Journal of Mathematical, Engineering and Management Sciences, 5(5), 854-868. https://doi.org/10.33889/IJMEMS.2020.5.5.066

Varela, L., Araújo, A., Ávila, P., Castro, H., & Putnik, G. (2019). Evaluation of the relation between lean manufacturing, industry 4.0, and sustainability. Sustainability, 11(5). https://doi.org/10.3390/su11051439

Wagner, T., Herrmann, C., & Sebastian, T. (2017). Industry 4.0 impacts oon lean production systems. Procedia CIRP, 63, 125-131. https://doi.org/10.1016/j.procir.2017.02.041

Wan, J., Cai, H., & Zhou, K. (2015). Industrie 4.0: Enabling technologies. Proceedings of 2015 International Conference on Intelligent Computing and Internet of Things, 135-140. https://doi.org/10.1109/ICAIOT.2015.7111555

Womack, J.P., & Jones, D.T. (1997). Lean Thinking-Banish Waste and Create Wealth in your Corporation. Journal of the Operational Research Society, 48(11), 1148-1148. https://doi.org/10.1038/sj.jors.2600967

Womack, J.P., Jones, D.T., & Roos, D. (2007). The Machine That Changed the World. Free Press.

Xu, Y., & Chen, M. (2017). An Internet of Things based framework to enhance Just-In-Time manufacturing. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 232(13), 2353-2363. https://doi.org/10.1177/0954405417731467

Yadav, N., Shankar, R., & Singh, S.P. (2020). Impact of Industry4.0/ICTs, Lean Six Sigma and quality management systems on organisational performance. TQM Journal, 32(4), 815-835. https://doi.org/10.1108/TQM-10-2019-0251

Zuehlke, D. (2010). SmartFactory-Towards a factory-of-things. Annual Reviews in Control, 34(1), 129-138. https://doi.org/10.1016/j.arcontrol.2010.02.008

Downloads

Published

2023-12-23

How to Cite

Koteswarapavan, C., & Pattanaik , L. N. (2023). A novel tool-input-process-output (TIPO) framework for upgrading to lean 4.0. International Journal of Production Management and Engineering, 12(1), 65–77. https://doi.org/10.4995/ijpme.2024.19723

Issue

Section

Papers