A dynamic lean assessment tool considering system type and current state




Tamma, Saumya

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For companies implementing lean manufacturing techniques, the start-up phase is usually one of the most difficult stages. Although many of the companies know that lean manufacturing is beneficial, they may not know how and where to start its implementation effectively. In order to achieve leanness in a company, following a lean roadmap is a common and effective way. The lean roadmap leads the company in a systematic way of improving its processes and reducing wastes in the company. In order to identify a company's current position, a lean assessment tool is necessary which will help a company in knowing their leanness level. A conventional lean assessment tool typically uses a lean roadmap which is predefined for certain industries. Consequently, many lean assessment tools have been developed which focus only on a limited scope of application. In this research, a web-based dynamic lean assessment tool is proposed which categorizes the manufacturing sector into different business types based on volume and repetitiveness in order to create an adaptive assessment model. The model is developed using Analytical Hierarchy Process (AHP) and bilinear interpolation. Using the web-based lean assessment tool, a dynamic lean radar is generated which will guide the company in applying the right tool at the right time to the right system. On the contrary to the conventional lean assessment tools and roadmaps, the dynamic lean radar is totally adaptive based on the company's current state and business type. This web-based tool is built on PHP and MySQL platform. This web-based platform will provide the user with an advantage on easy access and elimination of need to store the information in paper format, and it is more user-friendly. The effectiveness of the dynamic lean radar over the static lean roadmaps is verified by simulating a hypothetical case of a manufacturing company, based on a real example, using ARENA simulation software. The effectiveness of the dynamic lean radar is then examined by statistical analysis of the results obtained from the ARENA simulation. Performance measures such as throughput, defect rate, wait time, WIP are noted down in order to compare the effectiveness of the dynamic lean radar with the traditional lean assessment tool.


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arena simulation, Dynamic lean roadmap, Lean Assessment, lean manufacturing



Mechanical Engineering