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Lean Manufacturing and Industry 4.0

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A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Industrial Systems".

Deadline for manuscript submissions: closed (28 February 2023) | Viewed by 35330

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Special Issue Editors

Dr. Luís Pinto Ferreira

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Chief Guest Editor

Department of Mechanical Engineering, ISEP–School of Engineering, Polytechnic of Porto, 4200-465 Porto, Portugal
Interests: lean manufacturing; manufacturing systems; discrete event simulation; simulation and optimization
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Paulo Ávila

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Co-Guest Editor

Department of Mechanical Engineering, ISEP – School of Engineering, Polytechnic of Porto, Porto, Portugal
Interests: Innovation, sustainability; manufacturing and management; learning organization; organizational behaviour and development; virtualization

Prof. Dr. João Bastos

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Co-Guest Editor

Department of Mechanical Engineering, ISEP – School of Engineering, Polytechnic of Porto, Porto, Portugal
Interests: production planning; scheduling; meta-heurisitcs; machine learning Tools

Dr. Francisco J. G. Silva

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Co-Guest Editor

Department of Mechanical Engineering, ISEP–School of Engineering, Polytechnic of Porto, 4200-072 Porto, Portugal
Interests: tribology; coatings; manufacturing processes
Special Issues, Collections and Topics in MDPI journals

Prof. José Carlos Sá

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Co-Guest Editor

Department of Mechanical Engineering, ISEP—School of Engineering, Polytechnic of Porto, 4200-465 Porto, Portugal
Interests: industrial management; lean; six-sigma; processes improvement; safety; sustainability
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Marlene Brito

E-Mail Website
Co-Guest Editor

Department of Mechanical Engineering, ISEP – School of Engineering, Polytechnic of Porto, Porto, Portugal
Interests: ergonomics; logistics; lean manufacturing; operations management

Special Issue Information

Dear Colleagues,

The increasing application of innovative digital technologies has lead to a push for major changes in manufacturing during the era of Industry 4.0. As these changes coincide with the increasing demand for sustainability, there has been a strong case for the application of lean methodologies in all aspects of the manufacturing process. Lean manufacturing is a production method aimed primarily at reducing times within the production system as well as response times from suppliers and to customers. As the application of lean methods is quite broad, it has attracted much attention of many experts in the fields of manufacturing, supply chain management, production simulation, optimization, management and green technologies.

This Special Issue seeks original research papers focusing on advances in applications of lean manufacturing methodologies and Industry 4.0 technologies. We hope that this Special Issue will be useful and informative to both researchers and practitioners. We also hope to inspire readers with promising new ideas and directions for future research.

Prof. Dr. Luís Pinto Ferreira
Chief Guest Editor

Prof. Dr. Paulo Ávila
Prof. Dr. João Bastos
Prof. Dr. Francisco J. G. Silva
Prof. José Carlos Sá
Prof. Dr. Marlene Brito
co-Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Machines is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

lean manufacturing
lean optimization techniques
sustainable manufacturing
Industry 4.0
digitalization

Published Papers (12 papers)

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Research

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18 pages, 9245 KiB

Open AccessArticle

Data Science for Industry 4.0 and Sustainability: A Survey and Analysis Based on Open Data

by Hélio Castro, Filipe Costa, Tânia Ferreira, Paulo Ávila, Manuela Cruz-Cunha, Luís Ferreira, Goran D. Putnik and João Bastos

Machines 2023, 11(4), 452; https://doi.org/10.3390/machines11040452 - 03 Apr 2023

Cited by 2 | Viewed by 2171

Abstract

In the last few years, the industrial, scientific, and technological fields have been subject to a revolutionary process of digitalization and automation called Industry 4.0. Its implementation has been successful mainly in the economic field of sustainability, while the environmental field has been gaining more attention from researchers recently. However, the social scope of Industry 4.0 is still somewhat neglected by researchers and organizations. This research aimed to study Industry 4.0 and sustainability themes using data science, by incorporating open data and open-source tools to achieve sustainable Industry 4.0. To that end, a quantitative analysis based on open data was developed using open-source software in order to study Industry 4.0 and sustainability trends. The main results show that manufacturing is a relevant value-added activity in the worldwide economy; that, foreseeing the importance of Industry 4.0, countries in America, Asia, Europe, and Oceania are incorporating technological principles of Industry 4.0 in their cities, creating so-called smart cities; and that the industries that invest most in technology are computers and electronics, pharmaceuticals, transport equipment, and IT (information technology) services. Furthermore, the G7 countries have a prevalent positive trend for the migration of technological and social skills toward sustainability, as it relates to the social pillar, and to Industry 4.0. Finally, on the global scale, a positive correlation between data openness and happiness was found. Full article

(This article belongs to the Special Issue Lean Manufacturing and Industry 4.0)

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17 pages, 5741 KiB

Open AccessArticle

Lean Manufacturing in Industry 4.0: A Smart and Sustainable Manufacturing System

by Benedictus Rahardjo, Fu-Kwun Wang, Ruey-Huei Yeh and Yu-Ping Chen

Machines 2023, 11(1), 72; https://doi.org/10.3390/machines11010072 - 06 Jan 2023

Cited by 9 | Viewed by 6730

Abstract

Background: Exploring the impact of combining Industry 4.0 technologies and Lean Manufacturing tools on organizational performance has been a popular topic in recent years. Design/Methodology/Approach: We propose a novel Smart and Sustainable Manufacturing System (SSMS) to provide management insights related to social impact, economic performance, and environmental impact. Some tools called Dynamic Lean 4.0 tools, such as Sustainable Value Steam Mapping (VSM), Extended Single Minute Exchange of Die (SMED), and Digital Poka-Yoke, are presented as outputs of synergistic relationships that optimize production processes. Originality/Research gap: There are few studies on the application of SSMS. This work presents a case study, aiming to fill this gap. A case study of vacuum degassing equipment fabrication is presented to demonstrate the improvement of utilizing the Define-Measure-Analyze-Improve-Control (DMAIC) method with Digital Poka-Yoke. Key statistical results: The implementation of this project increased the process capability index, Cpk, from 1.278 to 2. Practical Implications: It was concluded that the company successfully implemented a smart and sustainable manufacturing system, and created a safer working environment and new job opportunities, while increasing production yield from 99.44% to 100%, improving worker utilization, and directly saving NT$68,000. Limitations of the investigation: This paper is the use of a single case study. More applications of Dynamic Lean 4.0 tools in SSMS should be explored. Full article

(This article belongs to the Special Issue Lean Manufacturing and Industry 4.0)

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21 pages, 2739 KiB

Open AccessArticle

Multi-Model In-Plant Logistics Using Milkruns for Flexible Assembly Systems under Disturbances: An Industry Study Case

by Adrian Miqueo, Marcos Gracia-Cadarso, Marta Torralba, Francisco Gil-Vilda and José Antonio Yagüe-Fabra

Machines 2023, 11(1), 66; https://doi.org/10.3390/machines11010066 - 05 Jan 2023

Cited by 2 | Viewed by 1482

Abstract

Mass customisation demand requires increasingly flexible assembly operations. For the in-plant logistics of such systems, milkrun trains could present advantages under high variability conditions. This article uses an industrial study case from a global white-goods manufacturing company. A discrete events simulation model was developed to explore the performance of multi-model assembly lines using a set of operational and logistics Key Performance Indicators. Four simulation scenarios analyse the separate effects of an increased number of product models and three different sources of variability. The results show that milkruns can protect the assembly lines from upstream process disturbances. Full article

(This article belongs to the Special Issue Lean Manufacturing and Industry 4.0)

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18 pages, 1126 KiB

Open AccessArticle

Competitive Priorities and Lean–Green Practices—A Comparative Study in the Automotive Chain’ Suppliers

by Geandra Alves Queiroz, Alceu Gomes Alves Filho and Isotilia Costa Melo

Machines 2023, 11(1), 50; https://doi.org/10.3390/machines11010050 - 01 Jan 2023

Cited by 4 | Viewed by 2609

Abstract

For organizations to remain competitive, they must now adapt to sustainability requirements, which have become performance criteria for supplier selection for most original Equipment manufacturers (OEMs). In this sense, environmental performance is now included as a competitive priority throughout the supply chain. Therefore, this study aims to verify, through two case studies, the competitive priorities of two first-tier suppliers from the automotive chain that have adopted lean and green practices. The findings show that the quality priority is the main source of competitive advantage and the focus of the operations that are analyzed here, while the environmental priority is not considered the most important by the companies. However, it is still included as a priority. Furthermore, it is demonstrated that lean practices could generate compatibility for the environmental priority, even indirectly, while trade-offs can arise between priorities. Therefore, the integration between lean and green practices can facilitate the inclusion of the environmental priority into the operations strategy and management systems. Full article

(This article belongs to the Special Issue Lean Manufacturing and Industry 4.0)

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18 pages, 1527 KiB

Open AccessArticle

Modelling of Determinants of Logistics 4.0 Adoption: Insights from Developing Countries

by Shahbaz Khan, Rubee Singh, José Carlos Sá, Gilberto Santos and Luís Pinto Ferreira

Machines 2022, 10(12), 1242; https://doi.org/10.3390/machines10121242 - 19 Dec 2022

Cited by 3 | Viewed by 2252

Abstract

With the emergence of industry 4.0, several elements of the supply chain are transforming through the adoption of smart technologies such as blockchain, the internet of things and cyber-physical systems. Logistics is considered one of the important elements of supply chain management and its digital transformation is crucial to the success of industry 4.0. In this circumstance, the existing logistics system needs to be upgraded with industry 4.0 technologies and emerge as logistics 4.0. However, the adoption/transformation of logistics 4.0 is dependent on several determinants that need to be explored. Therefore, this study has the prime objective of investigating the determinants of logistics 4.0 adoption in the context of a developing country, specifically, India. Initially, ten determinants of logistics 4.0 are established after a survey of the relevant literature and the input of industry experts. Further, a four-level structural model is developed among these determinants using the Interpretive Structural Modelling (ISM) approach. In addition, a fuzzy Matrix of Cross-Impact Multiplications Applied to Classification (MICMAC) analysis is also conducted for the categorization of these determinants as per their driving and dependence power. The findings show that top management supports, information technology infrastructure and financial investment are the most significant determinants towards logistics 4.0 adoption. This study facilitates the supply chain partners to focus on these high-level determinants for the effective adoption of logistics 4.0. Moreover, the findings lead to a more in-depth insight into the determinants that influence logistics 4.0 and their significance in logistics 4.0 adoption in emerging economies. Full article

(This article belongs to the Special Issue Lean Manufacturing and Industry 4.0)

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15 pages, 1208 KiB

Open AccessArticle

Implementation of a Lean 4.0 Project to Reduce Non-Value Add Waste in a Medical Device Company

by Ida Foley, Olivia McDermott, Angelo Rosa and Manjeet Kharub

Machines 2022, 10(12), 1119; https://doi.org/10.3390/machines10121119 - 26 Nov 2022

Cited by 6 | Viewed by 2429

Abstract

The fourth industrial revolution, also referred to as Industry 4.0, has resulted in many changes within the manufacturing industry. The purpose of the study is to demonstrate how an Industry 4.0 project was scoped and deployed utilising Lean tools to reduce non-value add wastes and aid regulatory compliance. A case study research approach was utilised to demonstrate how the Lean Industry 4.0 project was implemented in a Medtech company to enhance Lean processes while increasing digitalisation. This research demonstrates that Industry 4.0 can enhance Lean, improve flow, reduce nonvalue add waste, and facilitate product lifecycle regulatory compliance to reduce defects, enhance quality, improve cycle time, and minimise reworks and over-processing. Lean and Industry 4.0 combined offer many benefits to the MedTech Industry. This research will support organisations in demonstrating how digital technologies can synergistically affect Lean processes, positively impact product lifecycle regulatory compliance, and support the industry in building a business case for future implementation of Industry 4.0 technologies. Full article

(This article belongs to the Special Issue Lean Manufacturing and Industry 4.0)

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14 pages, 611 KiB

Open AccessArticle

Improving Urgency-Based Backlog Sequencing of Jobs: An Assessment by Simulation

by Nuno O. Fernandes, Matthias Thürer, Mark Stevenson and Silvio Carmo-Silva

Machines 2022, 10(10), 935; https://doi.org/10.3390/machines10100935 - 14 Oct 2022

Viewed by 1110

Abstract

When order release is applied, jobs are withheld in a backlog from where they are released to meet certain performance targets. The decision that selects jobs for release is typically preceded by a sequencing decision. It was traditionally assumed that backlog sequencing is only responsible for releasing jobs on time, whereas more recent literature has argued that it can also support load balancing. Although the new load-based rules outperform time-based rules, they can be criticized for requiring workload information from the shop floor and for delaying large jobs. While some jobs will inevitably be delayed during periods of high load, we argue that this delaying decision should be under control of management. A simulation study of a wafer fab environment shows that a time-based rule matches the performance of more complex load-based backlog sequencing rules that have recently emerged. The new rule realizes the lowest percentage of tardy jobs if the lower bound that distinguishes between early and urgent jobs is set appropriately. It provides a simpler means of improving release performance, allowing managers to delay jobs that have adjustable due dates. Full article

(This article belongs to the Special Issue Lean Manufacturing and Industry 4.0)

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23 pages, 11088 KiB

Open AccessArticle

A Novel Robotic Manipulator Concept for Managing the Winding and Extraction of Yarn Coils

by Rúben Costa, Vitor F. C. Sousa, Francisco J. G. Silva, Raul Campilho, Arnaldo G. Pinto, Luís P. Ferreira and Rui Soares

Machines 2022, 10(10), 857; https://doi.org/10.3390/machines10100857 - 26 Sep 2022

Viewed by 1711

Abstract

Wire rope manufacturing is an old industry that maintains its place in the market due to the need for products with specific characteristics in different sectors. The necessity for modernization and performance improvement in this industry, where there is still a high amount of labor dedicated to internal logistics operations, led to the development of a new technology method, to overcome uncertainties related to human behaviour and fatigue. The removal of successive yarn coils from a twisting and winding machine, as well as cutting the yarn and connecting the other end to the shaft in order to proceed with the process, constitutes the main problem. As such, a mobile automatic system was created for this process, due to its automation potential, with a project considering the design of a 3D model. This novel robotic manipulator increased the useful production time and decreased the winding coil removal cycle time, resulting in a more competitive, fully automated product with the same quality. This system has led to better productivity and reliability of the manufacturing process, eliminating manual labor and its cost, as in previously developed works in other industries. Full article

(This article belongs to the Special Issue Lean Manufacturing and Industry 4.0)

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27 pages, 1055 KiB

Open AccessArticle

Improving the Shipbuilding Sales Process by Selected Lean Management Tool

by Zoran Kunkera, Nataša Tošanović and Nedeljko Štefanić

Machines 2022, 10(9), 766; https://doi.org/10.3390/machines10090766 - 02 Sep 2022

Cited by 8 | Viewed by 2584

Abstract

Market positioning, i.e., the competitiveness of European shipyards, depends a lot on the measures of continuously improving the business processes, therefore meeting the criteria of environmental protection and sustainable energy. Lean management enables ongoing improvements of all system processes by recognizing and removing the unnecessary costs of the same, i.e., those activities which do not contribute to the added value for the customer. In this paper, the authors research the magnitude of improvements in the shipbuilding sales process achieved by applying the Lean tool “Value Stream Mapping” (VSM). The example of analysing the informational stream of the studied European shipyard’s existing sales process, performed by implementing the VSM, has defined the measures to decrease the losses in the process, with an emphasis on waiting time in internal and external communication. Upon VSM of the future state, measuring improvements realised by applying key performance indicators began. Significant cost savings in the sales process and the simultaneous increase of productivity of the employees participating in those process activities have been noted, as well as the substantial growth in sales and the shipyard’s income. Full article

(This article belongs to the Special Issue Lean Manufacturing and Industry 4.0)

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15 pages, 906 KiB

Open AccessArticle

Analysis of the Implementation of the Single Minute Exchange of Die Methodology in an Agroindustry through Action Research

by Murilo Augusto Silva Ribeiro, Ana Carolina Oliveira Santos, Gabriela da Fonseca de Amorim, Carlos Henrique de Oliveira, Rodrigo Aparecido da Silva Braga and Roberto Silva Netto

Machines 2022, 10(5), 287; https://doi.org/10.3390/machines10050287 - 20 Apr 2022

Cited by 9 | Viewed by 3273

Abstract

This work aims to implement and analyze the effect of the Single Minute Exchange of Die (SMED) implementation in the bean packaging operation in a company in east Minas Gerais, Brazil. Design/Methodology/Approach: The research methodology used was action research. Two cycles of action research were conducted; the first to carry out phase one of SMED, and the second to execute phases two and three. Originality/Research gap: There are few studies on the application of Lean Manufacturing tools in agroindustry. Some works present case studies, mainly in the food supply chain aiming to fill this gap. Regarding SMED applied in agribusiness, no work was found. Key statistical results: The implementation of this methodology allowed the reduction of setup time by around 58%, the distance travelled by operators in the process by approximately 50%, in addition to gains in a production capacity of 14%. Practical Implications: It is concluded that the application of the methodology caused an increase in the company’s productivity, as it was possible to obtain gains in productive capacity without changing the amount of hours worked or the number of employees involved in the production process. Limitations of the investigation: This methodology was applied only once and the challenges encountered were not documented. Full article

(This article belongs to the Special Issue Lean Manufacturing and Industry 4.0)

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18 pages, 2094 KiB

Open AccessArticle

Developing and Implementing a Lean Performance Indicator: Overall Process Effectiveness to Measure the Effectiveness in an Operation Process

by Lisbeth del Carmen Ng Corrales, María Pilar Lambán, Paula Morella, Jesús Royo, Juan Carlos Sánchez Catalán and Mario Enrique Hernandez Korner

Machines 2022, 10(2), 133; https://doi.org/10.3390/machines10020133 - 12 Feb 2022

Cited by 4 | Viewed by 3467

Abstract

The purpose of this paper is to build up and implement a framework of a lean performance indicator with collaborative participation. A new indicator derived from OEE is presented, overall process effectiveness (OPE), which measures the effectiveness of an operation process. The action research (AR) methodology was used; collaborative work was done between researchers and management team participation. The framework was developed with the researchers’ and practitioners’ experiences, and the data was collected and analyzed; some improvements were applied and finally, a critical reflection of the process was done. This new metric contributes to measuring the unloading process, identifying losses, and generating continuous improvement plans tailored to organizational needs, increasing their market competitiveness and reducing the non-value-add activities. The OEE framework is implemented in a new domain, opening a new line of research applied to logistic process performance. This framework contributes to recording and measuring the data of one unloading area and could be extrapolated to other domains for lean performance. It was possible to generate and validate knowledge applied in the field. This study makes collaborative participation providing an effectiveness indicator that helps the managerial team to make better decisions through AR methodology. Full article

(This article belongs to the Special Issue Lean Manufacturing and Industry 4.0)

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Review

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25 pages, 382 KiB

Open AccessReview

Lean and Industry 4.0: A Review of the Relationship, Its Limitations, and the Path Ahead with Industry 5.0

by André Moraes, André M. Carvalho and Paulo Sampaio

Machines 2023, 11(4), 443; https://doi.org/10.3390/machines11040443 - 31 Mar 2023

Cited by 6 | Viewed by 2919

Abstract

This article aims to analyze the relationship between Lean and Industry 4.0, further exploring the opportunities for integration with the new concept of Industry 5.0. Departing from a literature review, it shows how the relationship between Industry 4.0 and Lean is—while unanimously positive—clearly orientated towards the more technological aspects. In this scenario, most studies on this relationship highlight the technological side of organizations, emphasizing the integration of Industry 4.0 technology to augment Lean methodologies and tools. As such, most of the apparent value of this relationship derives from the use of technology, and relatively limited inputs input are found on issues related to the human and social factors of organizations—such as leadership, people, integration, and training for new roles and new tasks. In the face of this reality, we evaluate the potential for integration between Lean and Industry 5.0, arguing how Lean may offer a proper perspective to support sustainability, resilience, and human orientation in Industrial contexts. Full article

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