A Multi-Criteria Decision-Making Model for the Justification of Lean Manufacturing Systems

Analyzing the Implementation of Lean Manufacturing Systems

by Sagar Shinde*, Prof. (Dr.) Sanjay S. Chaudhary, Prof. (Dr.) Abhijeet B. Auti,

- Published in Journal of Advances and Scholarly Researches in Allied Education, E-ISSN: 2230-7540

Volume 13, Issue No. 2, Jul 2017, Pages 620 - 623 (4)

Published by: Ignited Minds Journals


ABSTRACT

On the other hand, some managers' bank on highly sophisticated, technology based systems such as Flexible Manufacturing Systems (FMS), Com-puter Integrated Manufacturing Systems (CIMS), Information Systems (IS) that enable e-business through the use of software packages for Enterprise Resource Planning (ERP), Supply Chain Management (SCM), Customer Relationship Management (CRM) etc. But an intriguing question that has not been answered completely is 'how do managers make a decision of implementing a 'management based and people oriented philosophy and practice' (say LMS) or a technically sophisticated system (say CIMS)?' Implementing such massive change management programmes require a strong justification for the managers to convince the top management, as it involves huge investment and creates a longstanding impact on various resources. But such justification problems are quite complex. Traditional techniques cannot be applied as they do not ac-count for intangible factors and benefits offered, which necessitate the use of Multi-Criteria Decision-Making (MCDM) models. Hence in this paper, an attempt has been made to demonstrate the application of a MCDM model, namely, the Performance Value Analysis (PVA) to analyse the alternatives (i.e., change management programmes) based on its impact on various performance measures of an organisation. A detailed algorithm of the PVA model is demonstrated using a case situation, which showed that LMS is the best for the given situation, as it results in overall improvement in the performance of the organization.

KEYWORD

multi-criteria decision-making, justification, lean manufacturing systems, management philosophy, change management programs, performance value analysis, intangible factors, traditional techniques, flexible manufacturing systems, computer integrated manufacturing systems

INTRODUCTION

Lean Production System centers around long haul objectives, even at the expense of transient monetary objectives. Cost decrease is the real driver in lean creation framework. LPS consistently begins with increasing the value of customers, society and economy and this rule isn't just for the item and plan, however in each capacity of the organization.

Process

The correct process will deliver right outcomes and making proceeds with stream will surface the concealed waste issues. Nonstop stream targets bringing down towards zero sitting tight time for the following process

People and Partners

Create individuals and accomplices to create organization. Toyota trusts in developing pioneers, who can comprehend the work, live with the way of thinking and instruct it to other people. In Toyota, pioneers are developed and they are not acquired from different organizations.

Problem fathoming

Creating critical thinking capacities over the organization is substantially more imperative to challenge waste disposal in the process. Critical thinking action ought to occur inside the organization at different levels, beginning from top administration to the administrators. Administrators and first line manager should concentrate on taking care of the present issue. Center administration should concentrate in part on the present issue and essentially on tomorrow's potential.

Toyota wonder

In light of above dialog on 4Ps, creator took a group of 16 individuals from capacities like manufacturing, quality, designing, buy, showcasing, (Total Quality Control) TQC, and had meeting to generate new

session, and shared it beneath which is simple. There is a million dollar question that, "Why the world's biggest Toyota car maker develops persistently and makes enormous benefits while its greatest rivals battle for survival? The lean upgrades are not being supported because of the accompanying reasons and the organization vacillates. Alluding to most organization never get profound enough into lean process to accomplish genuine outcomes. The vast majority of the organization see what's more, need verdant green simple stuff, "The lean apparatuses and strategies ". Be that as it may, the part we truly need is beneath the surface and it requires diligent work and exertion to get to itby seeing momentary objectives and fulfilled.

Figure:1. Carrot Model of TPS

REVIEW OF LITERATURE

The examination by Ramarapu, Mehra, and Frolick(2013) remains as one of only a handful couple of instances of a literature survey focused on LP execution, yet it depended on articles distributed over 20 years back. Ramarapu, Mehra, and Frolick (2016) finished up, in light of 105 examinations, that five categories of elements are basic for LP usage: disposal of waste, production technique, quality control and quality improvement, the board responsibility and employee interest, and seller/provider support. In addition, they reasoned that the significant focal point of LP execution research was theoretical based investigations, and that observational based examinations were later. A not very many investigations managed reenactment and numerical models As per Womack and Jones (2013), lean is characterized as a process that incorporates five steps: the initial step is characterizing client esteem, at that point characterizing worth stream, making it 'stream', set up draw, and the last step is making progress toward perfection. organization through certain measures. For instance, Karlsson and Ahlstrom (2016) have utilized a lot of measures condensed in a type of agenda to survey the degree of leanness. Gunther et al. (2016) pursued this methodology and broke down the part kitting issue looked in semi mechanized printed circuit board get together. James – Moore and Gibbons (2014) portrayed the standards of Lean production are currently entrenched and it is a reasonable process inside the vehicle business, yet additionally in the at fit hesitant airplane business. Rao et al (2013) inspected and assessed vital and operational level achievement factors, advantages and cost to create techniques of actualizing Concurrent Engineering (CE). Initial, a few achievement elements to execute CE are recognized dependent on literature survey. At that point the AHP model is detailed and used to survey the achievement factors, advantages and expenses so as to create systems to actualize CE in Hong Kong hardware products manufacturing organizations. Likewise a similar model is utilized to decide the advantages/cost proportions and to choose whether or not to actualize CE in the Hong Kong gadgets industry. Ahlstrom (2014) inspected whether any succession of manufacturing improvement is started to improve manufacturing execution. This finding assembled the standards of lean production in to four unique categories, contingent upon whether the administration committed exertion and assets to the standards. They presumed that there are arrangements wherein lean production standards are executed, however in parallel, the executives likewise needs to give endeavors and assets. The term 'leanness' was translated differently in the literature. Naylor et al. (2012) use 'leanness' to depict the process of acknowledging lean standards while presenting the idea of 'leagility'. This definition has been refered to by many after distributions on leagility, including Mason-Jones et al. (2000). They additionally expressed that 'leanness is a way of thinking proposed to fundamentally lessen cost and process duration all through the whole worth chain while proceeding to improve item execution'. McIvor (2001) utilizes 'all out leanness' to infer a splendidly lean state with a few key components of lean stock. Soriano-Meier and Forrester (2002) assess the level of leanness of manufacturing firms utilizing nine factors recommended by Karlsson and Ahlstrom (2013). Numerous examinations have been done on effect of lean manufacturing via Landsberghis et al (2011), quality administration on laborers wellbeing. Their examination uncovered that the execution of lean production lead to heightened work pace and requests, though choice frame of mind stayed low. This thusly prompted expanded solid skeletal issue to the laborers. Scientists use reenactment models with a few presentation measurements to evaluate potential advantages of lean execution. When all is said in done, a gathering of measurements are expected to plot the general leanness level since every measurement contributes just halfway. Be that as it may, it is hard to blend the gathering of measurements into a coordinated leanness measure because of the various natures of the measurements. Some are progressively self-clarifying, for example, imperfection rates, where zero deformity is consistently the objective. In any case, not all measurements are understandable without benchmarking. For instance, stock turn is a significant exhibition record for in the nick of time (JIT) rehearses. Toyota topped at 22.9 in 1998; WalMart accomplished 7.7 in 2003; Dell arrived at 88 of every 2005 (Schonberger 2005). Every one of the three organizations are among the accepted procedures in their field in spite of the fact that the numbers vary definitely.

CONCLUSION

In factor investigation of components contributing for compelling execution of LPS, subsequent to performing factor examination the absolute number of 25 factors in the investigation decreased to 2 huge factors by dropping the staying 23 inconsequential elements dependent on certain model. These two huge elements techno condition, and ergonomically structured work strategies were considered in two distinctive contextual analyses, which demonstrates that a critical increment in general working state of the business which thus prompted the expansion in the profitability. At last it is prescribed to think about these couple of basic components for successful usage.

FUTURE SCOPE OF RESEARCH

• The factors contributing for amazing execution of LPS can be furthermore explored and this can be moreover loosened up to help undertakings as well. • After contemplating these parts for convincing execution of LPS, fitting logical gadgets and techniques like Fuzzy Topsis can be applied to measure the leanness of the organization. Relevant examinations can be coordinated to measure the leaness of the organization and there is a huge amount of degree of work is there to join this in future. are used in essential authority of LPS execution. There won't be a lone logical model for LPS execution. A single model can be made in future. • Methods to perceive the tremendous components contributing for ground-breaking execution of LPS isn't discussed in detail. There is a degree for point by point talk.

REFERENCES

1. Dilanthi M. G. S. (2015). "Calculated Evolution Lean Manufacturing: A Review of Literature", International Journal of Economics, Commerce and Management, Vol. III, No.10. 2. Donatelli A. J. and Harris G. A. (2001). "Consolidating worth stream mapping and discrete occasion simulation.In: Proceedings of the Huntsville recreation gathering", The Society for Modeling and Simulation International, 3–4, October 2001, San Diego 3. Durairaj M., Sudharsun D., Swamynathan N. (2013). "Examination of Process Parameters in Wire EDM with Stainless Steel utilizing Single Objective Taguchi Method and Multi Objective Gray Relational Grade", Procedia Engineering, Vol. 64, pp. 868–877. 4. Fynes B. (1994). what's more, Ennis S. "From Lean Production to Lean Logistics: The instance of Microsoft Ireland", European management Journal, Vol. 12, No. 3, pp. 322-331. 5. Farzad Behronzi and Kuan Yew Wong (2011). "Lean execution assessment of manufacturing frameworks: A dynamic and inventive methodology," Procedia Computer Science, Vol.3, pp. 388–395. 6. Giuliano Almeida Marodin and Tarcisio Abreu Saurin: Implementing lean production frameworks: look into zones and open doors for future investigations." 7. Worldwide Journal of Production Research", 2013 DOI:10.1080/00207543.2013.826831 8. Geir Ringen, Silje Aschehoug, Halvor Holtskog and Jonas Ingvaldsen (2014). ―Integrating Quality and Lean into a Holistic Production System‖, Procedia CIRP, Vol.17, pp. 242–247. 9. Gunther H.O., Gronalt M. and Piller F. (1996). Compact kitting in semi-computerized printed circuit board get

10. Gyekye S. (2005). Laborers Perceptions of Workplace Safety and Job Satisfaction", International Journal of Occupational Safety and Ergonomics (JOSE), Vol. 11, No. 3, pp. 291–302. 11. Hambali S. M. Sapuan (2010). "Material determination of polymeric composite car guard utilizing AHP", Journal of Central south college of Technology, Vol 17, pp. 244–216. 12. Hines P., Holweg M. and Rich N. (2004). Learning to Evolve. A Review of Contemporary Lean Thinking", International Journal of Operations and Production Management, Vol. 24, No.10 pp. 994–1011. 13. Hoda E. L. Maraghy and Ahmed M. Deif (2014). ―Dynamic displaying of effect of lean arrangements on production leveling practicality, CIRP Annals", Journal of Manufacturing Technology, Vol.63, pp. 389–392.

Corresponding Author Sagar Shinde*

PhD Student, Maharishi University of Information Technology, Lucknow