7/23/2019 Establishment of Relationships in a Lean Manufacturing System

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Proceedings of the 2010 Industrial Engineering Research Conference

A. Johnson and J. Miller, eds.

Establishment of Relationships in a Lean Manufacturing System

Ernest Iwuchukwu, Rupy Sawhney, Louis Ali, Gilberto Carrera, Robert Uncapher, Sasikumar Naidu

Industrial and Information Engineering

University of Tennessee

Knoxville TN 37996

Abstract

A model to analyze lean systems reliability is developed based on the premises that lean systems require four critical

resources; personnel, equipment, schedule and materials. Literature shows that each of these critical resources is

independently analyzed. This paper develops relationships within these four critical resources utilizing Fault Tree

Diagram. Interactions within events in these resources are captured with design structure matrix. The degree of each

established interaction is estimated. This approach, when applied to lean implementation, is expected to enable

experts to direct their efforts and resources to prevent undesired events that have the greatest impact on the system.

Keywords

Industrial engineering, lean manufacturing

1. Introduction

An organizations ability to survive depends on how well the organization adapts to demands imposed by a changing

environment. Companies use different manufacturing strategies and action programs to consistently provide

products and services that are competitive with regards to quality, price, time and agility [1]. In recent years, firms

attempting to remain competitive in a global economy have turned to lean production. Lean production is a

methodology that seeks to minimize the resources required for production by eliminating waste (non-value added

activities) that inflate costs, lead times and inventory requirements, while emphasizing the use of preventive

maintenance, quality improvement programs, pull systems, flexible work forces and production facilities [2]. A lean

production system is composed of four critical components: personnel, materials, equipment, and schedules [3]. The

basic stability in the simplest sense implies general predictability and consistent availability in terms of manpower,

machines, materials, and methods - the 4Ms [4]. The 4ms of manufacturing are similar to the four critical

components of a lean production system, as shown in table 1, which determine the overall stability or reliability of a

lean production system.

Table 1: 4Ms and Critical Components

4 Ms of Manufacturing Critical Components

Manpower Personnel

Materials Materials

Machine Equipment

Methods Schedules

1.1 Critical Components:

Some lean practices were combined into 4 lean bundles by Shah et al [5] and these bundles underscore the critical

components to some extent. Personnel include the workforce and their capabilities and skills required to implement

lean. In practice, employees are involved in job rotation, job design, job training and cross training programs.

Employee morale is increased by a variety of measures, and employees are involved in decision-making. On the

other hand employees complain that lean implementation causes a decline in the working conditions. Therefore,