Lean road transportation – a systematic method for the improvement of road transport operations

Road transportation has become an important factor in international trade and the management of supply chains. However, this form of product logistics has generally been considered inefficient. Traditionally, practical inefficiencies of road transportation have been addressed through mathematical modelling, operations research-based methods and simulation. This paper presents an alternative systematic approach to improve road transport operations based on lean thinking and the reduction of the seven transportation extended wastes. To do this, the paper reviews the extant literature in the area of lean road transportation, providing a structured research definition of the application of lean thinking in road transport operations and hence guidance on the limited research conducted in this field. The systematic lean transportation method is then presented and empirically tested through a case study in a Mexican firm. The results obtained from the case study indicate that the proposed systematic lean method is an effective alternative for the improvement of road transport operations, with the number of distribution routes and distance travelled being reduced by 27 and 32%, respectively. The proposed method can be used by organisations as a guide to help them improve their road transport operations. In addition, the paper’s aim is to contribute by stimulating scholars to further study the application of lean thinking and waste reduction in road transport operations.     

Green and lean: a Gemba–Kaizen model for sustainability enhancement

Abstract

Despite the encouraging results obtained from the application of Green Lean, organizations have found the integration of Green and Lean, and their implementation as an integrated approach, challenging. This paper therefore presents a model for integrating Lean and Green based on the Gemba-Kaizen approach. The proposed model was developed on the basis of a through literature review on Gemba and Kaizen, conducted on peer reviewed journal articles and pragmatic books, and the more than 40 years of accumulated experience of the authors as academics, researchers, industrialists and consultants. The model was validated through two cases study in the aerospace and automotive industries. The results showed that the proposed model helped the case organizations to reduce the consumption of resources and improve their environmental performance. The proposed model can be the basis for further research on Lean and Green, contributing to help organizations to improve their sustainability performance.     

Rejects reduction in a retail bank using Lean Six Sigma

Lean Six Sigma (LSS) is a majestic process improvement methodology that has been proved to be a powerful management strategy across services. The influential synergy of Six Sigma and Lean aims at improving the processes, focusing on both rapid and robust improvements, reducing waste and variation in the process. LSS generates successful results in key performance indicators (KPIs) based environments, where process data gets measured and leveraged for making essential management decisions. The aim of this paper is to highlight the importance of LSS in banking industry through a real-time process improvement study. The article establishes the literature for the need for LSS in banks detailing on customer facing metrics and process KPIs. An action-research study conducted in a retail bank is presented in LSS DMAIC methodology which reaped a benefit of INR 1.6 million and is a classic example of how LSS can bring bottom-line impact to an organisation, alongside contributing to the process improvement mind-set in employees.     

Decision support tool for lean product and process development

Lean and concurrent engineering (CE) are widely acknowledged business process improvement strategies. These strategies can improve processes, reduce costs, and cut waste enabling organisations to remain competitive. Lean manufacturing offers an enterprise-wide methodology that improves reliability and flexibility while reducing lead-times and inventory carrying costs. Companies in manufacturing and service sectors are focusing on integrating lean manufacturing methodology with other applications, so that, all their systems and processes are aligned. This article proposes a CE framework based on application of information technology and object-oriented methodology for lean manufacturing. This approach expected to give manufacturing companies an extra edge in today's competitive market. A case study is presented in this article to demonstrate the effectiveness of CE framework in a machine tool manufacturing company. CE practice was adopted for new products, to align the systems and processes of the company. Product development lead-time was found to decrease by more than 50% compared to similar development projects carried out by the company. The need for rework was found to be negligible and the development cost was reduced considerably.     

Visual management system to improve care planning and controlling: the case of intensive care unit

Health Lean Management (HLM) is usually implemented to enhance the operational performance in health care; nevertheless, scant attention is devoted to visual control and daily accountability processes. This paper aims at investigating how to adopt a visual management system to: plan and control patient journey in health care operations and perform a continuous improvement process. Conducting in-depth interviews and observations, participating in meetings and collecting documentation, the patient journey board and daily briefings of an Intensive Care Unit were studied and improved. In the patient journey board, the Plan, Do and Check phases were reported, distinguishing between actual and planned actions for the patient care. The daily meetings were organised and a continuous improvement board was also developed to solve specific issues (Act phase), by creating ad-hoc teams, involving the staff and reporting transparently on the board. Operational and sociotechnical performance, before and after the adoption of HLM, were assessed demonstrating the effectiveness and efficiency of visual management tools.     

Coordinated Logistics: Joint Replenishment with Capacitated Transportation for a Supply Chain

In this study, we consider the integrated inventory replenishment and transportation operations in a supply chain where the orders placed by the downstream retailer are dispatched by the upstream warehouse via an in‐house fleet of limited size. We first consider the single‐item single‐echelon case where the retailer operates with a quantity based replenishment policy, (r,Q), and the warehouse is an ample supplier. We model the transportation operations as a queueing system and derive the operating characteristics of the system in exact terms. We extend this basic model to a two‐echelon supply chain where the warehouse employs a base‐stock policy. The departure process of the warehouse is characterized in distribution, which is then approximated by an Erlang arrival process by matching the first two moments for the analysis of the transportation queueing system. The operating characteristics and the expected cost rate are derived. An extension of this system to multiple retailers is also discussed. Numerical results are presented to illustrate the performance and the sensitivity of the models and the value of coordinating inventory and transportation operations.     

Six things to manage--Designs

Transportation in reverse logistics (RL) plays a significant role and has impact on overall RL performance. Efficiency, effectiveness and impact are the distinct components of RL transportation. Balancing these components requires the implementation of an effective performance measurement (PM) system. The perspectives of balanced scorecard have been used where enterprises can link their performance to their transportation practices, which do not provide an understanding of the RL transportation operating objectives and the developing strategies through an analysis of stakeholders. This article proposes the comprehensive PM of transportation system, which is multi-angle perspective for RL enterprises. Recognising the multiple criteria nature of the problem, this article uses analytical hierarchy process methodology in order to find an overall comprehensive performance index, which is critical to the success of the RL transportation operations to assist logistics managers, researchers, transportation planners and decision-makers.     

A Lean Six Sigma framework for the reduction of ship loading commercial time in the iron ore pelletising industry

Evidence suggests that specifically designed frameworks to implement Lean Six Sigma (LSS) projects to tackle particular problems are more effective than ‘generic’ versions. This paper proposes an implementation framework to effectively deploy LSS to improve a key operation and performance indicator, i.e. ship loading commercial time, of one of the largest world producer of iron ore. This article therefore contributes with a refined framework to effectively implement LSS, and documents its successful application and effectiveness within the context of the case organisation. The LSS framework and project contributed in helping the studied organisation to improve both the capability of its ship loading process and commercial time by more than 30%, resulting in operational savings in the range of $300,000 USD per year. The systematic nature of the framework proposed also helped the organisation to establish a standardised routine to improve its operations. Managerial implications exposing the challenges faced during the implementation of LSS are also discussed to serve as lessons learnt to be considered in other LSS projects. Managers and engineers incharge of improving operations and processes can benefit from this paper as it can be used as a guide to direct the conduction of LSS projects and the empirical application of its principles and tools.     

Implementation of Lean Six Sigma framework with environmental considerations in an Indian automotive component manufacturing firm: a case study

Lean Six Sigma is a systematic data driven methodology that integrates two powerful business improvement strategies Lean Manufacturing and Six Sigma with the goal of removing wastes and reducing process variation. Lean Six Sigma has a positive effect on environmental performance as defect reduction and reducing process variation leads to reduction in raw material consumption, energy consumption and reduced scrap which in turn reduces the overall environmental impacts. In this context, this study uses a Lean Six Sigma framework with environmental considerations to reduce overall defects and environmental impacts concurrently to improve the firm’s operational and environmental performance. The framework is based on Define Measure Analyze Improve Control methodology where traditional Lean Six Sigma and environmental impact assessment tools are integrated to systematically deploy LSS strategies with environmental considerations. The framework is validated with an industrial case study conducted in an Indian automotive component manufacturing organisation and the inferences are derived. On successful deployment of the framework, the internal defects was brought down to 6000 ppm from 16,000 ppm and environmental impacts was reduced to 33 Pt from 42 Pt. Deployment of the developed framework helped in improving the firm’s sigma level and also reduced the overall environmental impacts.     

Improving patients’ satisfaction in a mobile hospital using Lean Six Sigma – a design-thinking intervention

Abstract

Lean Six Sigma (LSS) that offers a unique integration of Lean and Six Sigma has been accepted globally across services sectors. Previous studies that examined the application of LSS in healthcare were steered in traditional hospital settings. Apparently, there are no studies that highlight the application of LSS in mobile hospitals, an emerging trend in the healthcare sector. The aim of this article is to explore the applicability of LSS in a mobile hospital. The authors present a case study of improving patients’ satisfaction in a mobile hospital, through reducing turnaround time. Design-thinking intervention to LSS helped resolve a real-time problem using Define-Measure-Analyze-Design-Verify roadmap. This article contributes to the ‘healthcare quality” body of knowledge and is novel as it is the first of its kind of LSS application in a mobile hospital underpinning Design thinking. This study is unique as it demonstrates academia–industry collaboration in solving an organizational problem.     

Synergies and misalignments in lean and green practices: a logistics industry perspective

Abstract

This paper conducts an exploratory case study-based research in three companies to identify the main synergies and misalignments between Lean and Green in the context of a range of distribution networks operating globally, regionally and domestically. The research strategy applied by this study is exploratory multiple case studies in three companies, particularly in the road transport and logistics sector. Semi-structured interviews with 15 executives from three companies were conducted to identify activities within logistics operations leading to synergies and misalignment between Lean and Green practices. The outcome of the three cases shows that several improvements can be achieved by the simultaneous adoption of Lean and Green. The study contributes to the literature by extending the research in the logistics sector and providing examples from a wide variety of logistics operations on synergies and misalignments between Lean and Green practices. The findings and outcome of this study are a starting point for further research in the logistics sector.     

大规模灾害中基于聚类的医疗物资联合运送优化

应急响应中,往往出现救援物资供应节点与需求节点距离太远、关键道路损毁导致难以及时通过车辆运送物资到灾区等情景,此时直升飞机逐渐被用来运送关键应急资源（如医疗物资及医护人员）。然而,大规模灾害中难以使用直升飞机运送医疗物资到每个医疗救助点,通常考虑灾民的聚集性选择一定数量的应急中转点,以接收直升飞机运送的医疗物资,之后采用车辆运送物资到其覆盖的医疗救助点。针对该问题,提出一种基于聚类的两阶段医疗物资联合运输方法：第一阶段根据医疗救助点分布,采用模糊C-均值算法（FCM）进行应急中转点选择和医疗救助点划分,并针对FCM划分中存在的剩余容量不均衡问题,考虑容量约束提出一种改进划分方法（FCMwCC）,构建“直升飞机-车辆”医疗物资联合运输网络结构;第二阶段建立基于聚类的运送路线优化模型,确定从应急中转点到医疗救助点的具体运送路线。数值实验验证了提出方法和算法的有效性。     

A NEW LEARNING APPROACH TO PROCESS IMPROVEMENT IN A TELECOMMUNICATIONS COMPANY

Redesigning and improving business processes to better serve customer needs has become a priority in service industries as they scramble to become more competitive. We describe an approach to process improvement that is being developed collaboratively by applied researchers at US WEST, a major telecommunications company, and the University of Colorado. Motivated by the need to streamline and to add more quantitative power to traditional quality improvement processes, the new approach uses an artificial intelligence (AI) statistical tree growing method using customer survey data to identify operations areas where improvements are expected to affect customers most. This AI/statistical method also identifies realistic quantitative targets for improvement and suggests specific strategies predicted to have high impart. This research, funded in part by the Colorado Advanced Software Institute (CASI) to stimulate profitable innovations, has resulted in a practical methodology used successfully at US WEST to help set process improvement priorities and guide resource allocation decisions throughout the company.     

Bi-objective multi-resource scheduling problem for emergency relief operations

Abstract

Resource scheduling for emergency relief operations is complex as it has many constraints. However, an effective allocation and sequencing of resources are crucial for the minimization of the completion times in emergency relief operations. Despite the importance of such decisions, only a few mathematical models of emergency relief operations have been studied. This article presents a bi-objective mixed integer programming (MIP) that helps to minimize both the total weighted time of completion of the demand points and the makespan of the total emergency relief operation. A two-phase method is developed to solve the bi-objective MIP problem. Additionally, a case study of hospital network in the Melbourne metropolitan area is used to evaluate the model. The results indicate that the model can successfully support the decisions required in the optimal resource scheduling of emergency relief operations.     

Operationalising lean in healthcare: the impact of professionalism

Abstract

Lean is endorsed as policy in practice in the UK but the challenges and complexities affecting Lean in healthcare are still to be adequately assessed. Through a qualitative single case study of an NHS organisation implementing Lean, 43 interviews with multi-disciplinary team members involved in Lean were conducted. The progress of Lean is found to be inhibited as medical professionals have failed to engage or provide clinical leadership in supporting the trajectory of Lean. This resulted in limited outcomes, sustainability implications, and failed projects. Lean is challenged by complexity and this is evident in conflicts between professional identity, corresponding status and clinical/managerial relationships. Medical professionals as a group have received a limited focus in papers assessing the progress of Lean in Healthcare from an operational perspective. Going forward, strategies for mitigating the negative impact of this can be developed to support operational managers in the healthcare domain.     

一种能力外包且费用时变批量问题的启发式算法

当企业自身能力不能满足需求时考虑外包,可以有效提高企业的竞争力。一种带能力外包的多产品动态经济批量问题得以提出,并设定外包能力使用价格较高且费用时变。建立混合整数规划模型,通过约束松弛与模型分解,设计出一个基于拉格朗日松弛理论的启发式算法进行模型求解。大量随机实验表明,无论解的质量还是求解时间都表现较好。     

Lean Six Sigma applied to process performance and improvement model for the development of electric scooter water-cooling green motor assembly

Abstract

In response to the environmental issues triggered by global warming, worldwide companies gradually put the factor of carbon emission into the process of product lifecycle, developing green technology or adopting cleaner production aimed at sustainable development. Lean Six Sigma has advantages of cutting waste and facilitating process improvements as well as system analysis, helping enterprises create the overall business benefits in the value chain. Used in the renewable energy industry, it can promote the triple bottom line (TBL), the performance of sustainable production for corporate profit, social responsibility and environmental responsibility. Therefore, this work took the process performance of the electric scooter water-cooling green motor manufactured in Taiwan with the world’s highest density of scooters as a case study. The developed performance evaluation and improvement model for manufacturing scheduling and process quality achieved the goal of economic benefits of enhancing process quality performance by shortening manufacturing scheduling and reducing process variations with Lean Six Sigma. Besides, they could respond to the policy of energy saving and carbon reduction – replacing the traditional scooters of high-carbon emissions with the electric scooters of low emissions. Furthermore, they could bring enterprises into harmony with economic benefits, ecological benefits and social benefits.     

Implementing lean sigma in an Indian rotary switches manufacturing organisation

The manufacturing organisations have been witnessing a transformation in the manufacturing paradigm. Lean sigma and six sigma are the two business process improvement strategies widely employed by organisations to enhance their manufacturing performance. To achieve dramatic result in cost, quality and time, best strategies need to be applied to enhance the process performance. Lean sigma and six sigma are two powerful and effective strategies, enabling the organisation to overcome their weakness and for retaining their improvement. Lean sigma combines the variability reduction tools and techniques drawn from six sigma with the waste and non-value added elimination tools and techniques from lean manufacturing to achieve savings in the organisations. This study uses an integrated lean sigma framework to reduce the defects occurring in the final product, thereby contributing savings to the organisation. The proposed framework integrates lean tools within six sigma methodology to enhance the bottom-line results and to win customer loyalty. The implementation of the proposed framework shows dramatic improvement in key metrics and substantial financial savings to be generated by the organisation.     

Problem Formulation and Solution Mechanisms: A Behavioral Study of Humanitarian Transportation Planning

When dealing with urgent, ill‐defined problems, such as rapidly evolving emergency situations, operations managers have little time for problem formulation or solution. While the mechanisms by which humans formulate and solve problems have been described, mechanisms for rapid, concurrent formulating and solving are not well understood. This study investigates these mechanisms through a field study of transportation planning in a humanitarian response setting. The findings show that the problem is solved through greedy search and formulated through sensemaking, in which search enables updates to an evolving problem formulation, and the formulation directs and limits the search process. This study explores the implications of these findings for the development of better problem formulation processes and problem‐solving strategies for urgent and ill‐defined operations management problems.     

EFFECTS OF ENVIRONMENTAL MANAGEMENT SYSTEMS ON ENVIRONMENTAL MANAGEMENT PRACTICES AND OPERATIONS

To date, it is unclear as to how Environmental Management Systems (EMS) are implemented and what effects these systems have on other environmental and operational practices. This study reports empirical insights to EMS practices based on the largest EMS survey of manufacturing firms in the United States. The objective of the study is to test for a relationship between environmental management systems and perceived operations performance while considering direct and indirect effects of various environmental practices. The results of this study are supported by several field studies and provide a new source of information regarding EMS theory development. The results also indicate a positive relationship between an EMS, the environmental practices a firm engages, and operations performance measures.