Research Article
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Road-mapping for smart and lean tools with a sustainability perspective: A new model proposal

Year 2024, Volume: 2024 Issue: Erken Görünüm

Mehmet Akif Gündüz Sercan Demir Turan Paksoy

https://doi.org/10.26650/JTL.2024.1329972

Abstract

This paper introduces a pioneering model designed to evaluate the readiness and maturity of smart-lean manufacturing by seamlessly integrating sustainability principles. In the dynamic landscape of Industry 4.0, where digitalization and connectivity redefine manufacturing paradigms, the convergence of smart and lean principles emerges as a powerful strategy. However, existing frameworks often lack a comprehensive approach that incorporates sustainability. Our model addresses this gap, systematically assessing organizations’ smart-lean manufacturing capabilities and their alignment with sustainability goals.

The proposed model employs a novel algorithm to assess the relationship between the maturity of smart and lean tools and their economic, social, and environmental contributions. Through a carefully designed process, decision-makers determine correlation ratings, evaluate tool maturity, and calculate contribution gaps, providing a roadmap for prioritized implementation. To illustrate the model’s applicability, an anonymous case study is presented, showcasing the step-by-step application of the algorithm.

This contribution is significant for enterprises seeking operational excellence and competitive advantage in the Industry 4.0 era. By incorporating sustainable lean principles into the smart-lean framework, our model guides organizations in enhancing their capacity development and making informed investment decisions. This paper not only advances academic discourse but also offers a practical tool for industry practitioners navigating the complexities of smart-lean manufacturing, ensuring a sustainable and environmentally responsible approach in the pursuit of long-term performance improvements.

Keywords

Smart-lean manufacturing smart-lean capabilities smart-lean maturity smart-lean sustainability readiness and maturity model

References

  • Abobakr, M. A., Abdel-Kader, M., & Elbayoumi, A. F. (2022). Integrating S-ERP systems and lean manufacturing practices to improve sustainability performance: an institutional theory perspective. Journal of Accounting in Emerging Economies, (ahead-of-print). google scholar
  • Afum, E., Zhang, R., Agyabeng-Mensah, Y., & Sun, Z. (2021). Sustainability excellence: The interactions of lean production, internal green practices and green product innovation. International Journal of Lean Six Sigma, 12(6), 1089-1114. google scholar
  • Akbal, H., & Doğan, N. Ö. (2023). Lean and smart supply chain management in healthcare. In Handbook of Research on Quality and Competitiveness in the Healthcare Services Sector (pp. 1-26). IGI Global. google scholar
  • Ali, Y., Younus, A., Khan, A.U., & Pervez, H. (2020). Impact of Lean, Six Sigma and environmental sustainability on the performance of SMEs. International Journal of Productivity and Performance Management, 70(8), 2294-2318. google scholar
  • Alves, J. R. X., & Alves, J. M. (2015). Production management model integrating the principles of lean manufacturing and sustainability supported by the cultural transformation of a company. International Journal of Production Research, 53(17), 5320-5333. google scholar
  • Anderl, R. (2014). Industrie 4.0-advanced engineering of smart products and smart production. In Proceedings of international seminar on high technology (Vol. 19). google scholar
  • Ben Ruben, R., Vinodh, S., & Asokan, P. (2020). Development of structural equation model for Lean Six Sigma system incorporated with sustainability considerations. International Journal of Lean Six Sigma, 11 (4), 687-710. google scholar
  • Benkhati, A., Taleb, H., & Kumar, V. (2023). Linkages between smart, lean, and resilient manufacturing for sustainable development. Sustainable Production and Consumption, 27, 727-744. google scholar
  • Biedermann, H., Kinz, A., Bernerstatter, R., &Zellner, T. (2016). Lean smartmaintenance—Implementation in the process industry. Productivity Management, 21(2), 41-43. google scholar
  • Bokhorst, J. a. C., Knol, W. H., Slomp, J., & Bortolotti, T. (2022). Assessing to what extent smart manufacturing builds on lean principles. International Journal of Production Economics, 253, 108599. https://doi.Org/10.1016/j.ype.2022.108599 google scholar
  • Bortolotti, T., Gamberi, M., Pilati, F., & Regattieri, A. (2023). Integrating Smart Manufacturing to Lean: A Multiple-Case Study of the Impact on Shop-Floor Employees’ Autonomy and Empowerment. Sustainability, 15(5), 2451. google scholar
  • Burawat, P. (2019). The relationships among transformational leadership, sustainable leadership, lean manufacturing and sustainability perfor-mance in Thai SMEs manufacturing industry. International Journal of Quality & Reliability Management. google scholar
  • Cherrafi, A., Elfezazi, S., Chiarini, A., Mokhlis, A., & Benhida, K. (2016). The integration of lean manufacturing, Six Sigma and sustainability: A literature review and future research directions for developing a specific model. Journal of Cleaner Production, 139, 828-846. google scholar
  • Cherrafi, A., Elfezazi, S., Govindan, K., Garza-Reyes, J. A., Benhida, K., & Mokhlis, A. (2017). A framework for the integration of Green and Lean Six Sigma for superior sustainability performance. International Journal of Production Research, 55(15), 4481-4515. google scholar
  • Cherrafi, A., Elfezazi, S., Hurley, B., Garza-Reyes, J. A., Kumar, V., Anosike, A., & Batista, L. (2019). Green and lean: a Gemba-Kaizen model for sustainability enhancement. Production Planning & Control, 30(5-6), 385-399. google scholar
  • Chien, C.F., Hong, T.Y. and Guo, H.Z., 2017. An empirical study for smart production for TFT-LCD to empower industry 3.5. Journal of the Chinese Institute of Engineers, 40(7), pp. 552-561. google scholar
  • Choudhary, S., Nayak, R., Dora, M., Mishra, N., & Ghadge, A. (2019). An integrated lean and green approach for improving sustainability performance: a case study of a packaging manufacturing SME in the UK. Production planning & control, 30(5-6), 353-368. google scholar
  • Ciannella, S., & Santos, L. C. (2022). Exploring the influence of lean manufacturing practices on employee social sustainability. Social Responsibility Journal, 18(8), 1677-1691. google scholar
  • Dahmani, M., Barletta, I., Pellicciari, M., & Terzi, S. (2021). Smart circular product design strategies towards eco-effective production systems: A lean eco-design industry 4.0 framework. Sustainable Production and Consumption, 28, 1016-1033. google scholar
  • Dahmani, N., Benhida, K., Belhadi, A., Kamble, S. S., Elfezazi, S., & Jauhar, S. K. (2021). Smart circular product design strategies towards eco-effective production systems: A lean eco-design industry 4.0 framework. Journal of Cleaner Production, 320, 128847. https://doi.org/10.1016/j.jclepro.2021.128847 google scholar
  • Demir, S., & Paksoy, T. (2023). Just-in-Time and Lean Management. In Smart and Sustainable Operations and Supply Chain Management in Industry 4.0 (pp. 223-236). CRC Press. google scholar
  • Demir, S., Paksoy, T., & Kochan, C. G. (2020). A Conceptual Framework for Industry 4.0: (How is it Started, How is it Evolving Over Time?). In Logistics 4.0 (pp. 1-14). CRC Press. google scholar
  • Dhungana, D., Falkner, A., Haselböck, A. and Schreiner, H., 2015, July. Smart Factory Prod uct Lines: A Configuration Perspective on Smart Production Ecosystems. Proceedings of the 19th International Conference on Software Product Line, pp. 201-210. google scholar
  • Fiorello, M., Gladysz, B., Corti, D., Wybraniak-Kujawa, M., Ejsmont, K., & Sorlini, M. (2023). Towards a smart lean green production paradigm to improve operational performance. Journal of Cleaner Production, 413, 137418. https://doi.org/10.1016/j.jclepro.2023.137418 google scholar
  • Herscovici, A. (2018). New development: Lean thinking in smart cities. Public Money & Management, 38(4), 320-324. https://doi.org/10.1080/09540962.2018.1450924 google scholar
  • Hosseinizadeh Mazloumi, S., Moini, A., & Kermani, M. R. (2022). Designing synchronizer module in CMMS software based on lean smart maintenance and process mining. Journal of Quality in Maintenance Engineering. https://doi.org/10.1108/jqme-10-2021-0077 google scholar
  • Ku, C. C., Chien, C. F., & Ma, K. T., 2020. Digital transformation to empower smart production for Industry 3.5 and an empirical study for textile dyeing. Computers & Industrial Engineering, 142, 106297. google scholar Li, Y. (2019). Lean smart manufacturing in Taiwan-Focusing on the bicycle industry. Sustainability, 11(21), 5924. google scholar
  • Mahmood, Z., & Montagna, J. M. (2013). Making lean smart by using system-of-systems’ approach. Procedia CIRP, 7, 11-16. google scholar
  • NIST. 2018. Model Based Enterprise Program [online]. Available at: <www.nist.gov/programs-projects/model-based-enterprise-program> [Ac-cessed 29 May 2023] google scholar
  • Rahardjo, S., Kusumawardani, S., & Setiawan, A. I. (2023). A Framework of Sustainable Lean Manufacturing: Smart and Sustainable Manufac-turing System (SSMS). In Proceedings of the 10th International Conference on Operations and Supply Chain Management. google scholar
  • RöBler, M. P., & Haschemi, M. (2017). Smartfactory assessment (SFA). ZWF, 112(10), 699-703. https://doi.org/10.3139/104.111800 google scholar
  • Schmiedbauer, M., Landschützer, C., Witzmann, S., & Mörtl, M. (2020). Evolution of a Lean Smart Maintenance Maturity Model towards the new Age of Industry 4.0. Procedia CIRP, 93, 146-151. google scholar
  • Shahin, A., Al-Mezeini, T., Bazzi, W., & Merhi, M. (2020). Integration of Lean practices and Industry 4.0 technologies: smart manufacturing for next-generation enterprises. Journal of Manufacturing Technology Management, 31(1), 154-179. google scholar
  • Touriki, E., Grammenos, I., & Ploskas, N. (2021). A combined approach of smart, green, resilient, and lean manufacturing towards sustainable development. Sustainability, 13(1), 96. google scholar
  • Tripathi, D., Patnaik, B., Sarkar, B., & Srivastava, R. K. (2023). Lean, green, and smart manufacturing: An ingenious framework for enhancing the sustainability of operations management on the shop floor in industry 4.0. Computers & Operations Research, 138, 105276. google scholar
  • Trevino-Elizondo, R., Duran-Rivero, M., & Cantu-del Ângel, D. (2023). A Maturity Model to Become a Smart Organization Based on Lean and Industry 4.0 Synergy. Sustainability, 15(5), 2251. google scholar
  • Tsai, Y. C., Tseng, Y. C., Lee, Y. F., Chou, Y. H., Chang, J. W., & Lai, F. J. (2021). Use of the smart lean method to conduct high-quality integrated perioperative management prior to hospitalization. Scientific Reports, 11(1), 20569. google scholar

Year 2024, Volume: 2024 Issue: Erken Görünüm

Mehmet Akif Gündüz Sercan Demir Turan Paksoy

https://doi.org/10.26650/JTL.2024.1329972

Abstract

References

  • Abobakr, M. A., Abdel-Kader, M., & Elbayoumi, A. F. (2022). Integrating S-ERP systems and lean manufacturing practices to improve sustainability performance: an institutional theory perspective. Journal of Accounting in Emerging Economies, (ahead-of-print). google scholar
  • Afum, E., Zhang, R., Agyabeng-Mensah, Y., & Sun, Z. (2021). Sustainability excellence: The interactions of lean production, internal green practices and green product innovation. International Journal of Lean Six Sigma, 12(6), 1089-1114. google scholar
  • Akbal, H., & Doğan, N. Ö. (2023). Lean and smart supply chain management in healthcare. In Handbook of Research on Quality and Competitiveness in the Healthcare Services Sector (pp. 1-26). IGI Global. google scholar
  • Ali, Y., Younus, A., Khan, A.U., & Pervez, H. (2020). Impact of Lean, Six Sigma and environmental sustainability on the performance of SMEs. International Journal of Productivity and Performance Management, 70(8), 2294-2318. google scholar
  • Alves, J. R. X., & Alves, J. M. (2015). Production management model integrating the principles of lean manufacturing and sustainability supported by the cultural transformation of a company. International Journal of Production Research, 53(17), 5320-5333. google scholar
  • Anderl, R. (2014). Industrie 4.0-advanced engineering of smart products and smart production. In Proceedings of international seminar on high technology (Vol. 19). google scholar
  • Ben Ruben, R., Vinodh, S., & Asokan, P. (2020). Development of structural equation model for Lean Six Sigma system incorporated with sustainability considerations. International Journal of Lean Six Sigma, 11 (4), 687-710. google scholar
  • Benkhati, A., Taleb, H., & Kumar, V. (2023). Linkages between smart, lean, and resilient manufacturing for sustainable development. Sustainable Production and Consumption, 27, 727-744. google scholar
  • Biedermann, H., Kinz, A., Bernerstatter, R., &Zellner, T. (2016). Lean smartmaintenance—Implementation in the process industry. Productivity Management, 21(2), 41-43. google scholar
  • Bokhorst, J. a. C., Knol, W. H., Slomp, J., & Bortolotti, T. (2022). Assessing to what extent smart manufacturing builds on lean principles. International Journal of Production Economics, 253, 108599. https://doi.Org/10.1016/j.ype.2022.108599 google scholar
  • Bortolotti, T., Gamberi, M., Pilati, F., & Regattieri, A. (2023). Integrating Smart Manufacturing to Lean: A Multiple-Case Study of the Impact on Shop-Floor Employees’ Autonomy and Empowerment. Sustainability, 15(5), 2451. google scholar
  • Burawat, P. (2019). The relationships among transformational leadership, sustainable leadership, lean manufacturing and sustainability perfor-mance in Thai SMEs manufacturing industry. International Journal of Quality & Reliability Management. google scholar
  • Cherrafi, A., Elfezazi, S., Chiarini, A., Mokhlis, A., & Benhida, K. (2016). The integration of lean manufacturing, Six Sigma and sustainability: A literature review and future research directions for developing a specific model. Journal of Cleaner Production, 139, 828-846. google scholar
  • Cherrafi, A., Elfezazi, S., Govindan, K., Garza-Reyes, J. A., Benhida, K., & Mokhlis, A. (2017). A framework for the integration of Green and Lean Six Sigma for superior sustainability performance. International Journal of Production Research, 55(15), 4481-4515. google scholar
  • Cherrafi, A., Elfezazi, S., Hurley, B., Garza-Reyes, J. A., Kumar, V., Anosike, A., & Batista, L. (2019). Green and lean: a Gemba-Kaizen model for sustainability enhancement. Production Planning & Control, 30(5-6), 385-399. google scholar
  • Chien, C.F., Hong, T.Y. and Guo, H.Z., 2017. An empirical study for smart production for TFT-LCD to empower industry 3.5. Journal of the Chinese Institute of Engineers, 40(7), pp. 552-561. google scholar
  • Choudhary, S., Nayak, R., Dora, M., Mishra, N., & Ghadge, A. (2019). An integrated lean and green approach for improving sustainability performance: a case study of a packaging manufacturing SME in the UK. Production planning & control, 30(5-6), 353-368. google scholar
  • Ciannella, S., & Santos, L. C. (2022). Exploring the influence of lean manufacturing practices on employee social sustainability. Social Responsibility Journal, 18(8), 1677-1691. google scholar
  • Dahmani, M., Barletta, I., Pellicciari, M., & Terzi, S. (2021). Smart circular product design strategies towards eco-effective production systems: A lean eco-design industry 4.0 framework. Sustainable Production and Consumption, 28, 1016-1033. google scholar
  • Dahmani, N., Benhida, K., Belhadi, A., Kamble, S. S., Elfezazi, S., & Jauhar, S. K. (2021). Smart circular product design strategies towards eco-effective production systems: A lean eco-design industry 4.0 framework. Journal of Cleaner Production, 320, 128847. https://doi.org/10.1016/j.jclepro.2021.128847 google scholar
  • Demir, S., & Paksoy, T. (2023). Just-in-Time and Lean Management. In Smart and Sustainable Operations and Supply Chain Management in Industry 4.0 (pp. 223-236). CRC Press. google scholar
  • Demir, S., Paksoy, T., & Kochan, C. G. (2020). A Conceptual Framework for Industry 4.0: (How is it Started, How is it Evolving Over Time?). In Logistics 4.0 (pp. 1-14). CRC Press. google scholar
  • Dhungana, D., Falkner, A., Haselböck, A. and Schreiner, H., 2015, July. Smart Factory Prod uct Lines: A Configuration Perspective on Smart Production Ecosystems. Proceedings of the 19th International Conference on Software Product Line, pp. 201-210. google scholar
  • Fiorello, M., Gladysz, B., Corti, D., Wybraniak-Kujawa, M., Ejsmont, K., & Sorlini, M. (2023). Towards a smart lean green production paradigm to improve operational performance. Journal of Cleaner Production, 413, 137418. https://doi.org/10.1016/j.jclepro.2023.137418 google scholar
  • Herscovici, A. (2018). New development: Lean thinking in smart cities. Public Money & Management, 38(4), 320-324. https://doi.org/10.1080/09540962.2018.1450924 google scholar
  • Hosseinizadeh Mazloumi, S., Moini, A., & Kermani, M. R. (2022). Designing synchronizer module in CMMS software based on lean smart maintenance and process mining. Journal of Quality in Maintenance Engineering. https://doi.org/10.1108/jqme-10-2021-0077 google scholar
  • Ku, C. C., Chien, C. F., & Ma, K. T., 2020. Digital transformation to empower smart production for Industry 3.5 and an empirical study for textile dyeing. Computers & Industrial Engineering, 142, 106297. google scholar Li, Y. (2019). Lean smart manufacturing in Taiwan-Focusing on the bicycle industry. Sustainability, 11(21), 5924. google scholar
  • Mahmood, Z., & Montagna, J. M. (2013). Making lean smart by using system-of-systems’ approach. Procedia CIRP, 7, 11-16. google scholar
  • NIST. 2018. Model Based Enterprise Program [online]. Available at: <www.nist.gov/programs-projects/model-based-enterprise-program> [Ac-cessed 29 May 2023] google scholar
  • Rahardjo, S., Kusumawardani, S., & Setiawan, A. I. (2023). A Framework of Sustainable Lean Manufacturing: Smart and Sustainable Manufac-turing System (SSMS). In Proceedings of the 10th International Conference on Operations and Supply Chain Management. google scholar
  • RöBler, M. P., & Haschemi, M. (2017). Smartfactory assessment (SFA). ZWF, 112(10), 699-703. https://doi.org/10.3139/104.111800 google scholar
  • Schmiedbauer, M., Landschützer, C., Witzmann, S., & Mörtl, M. (2020). Evolution of a Lean Smart Maintenance Maturity Model towards the new Age of Industry 4.0. Procedia CIRP, 93, 146-151. google scholar
  • Shahin, A., Al-Mezeini, T., Bazzi, W., & Merhi, M. (2020). Integration of Lean practices and Industry 4.0 technologies: smart manufacturing for next-generation enterprises. Journal of Manufacturing Technology Management, 31(1), 154-179. google scholar
  • Touriki, E., Grammenos, I., & Ploskas, N. (2021). A combined approach of smart, green, resilient, and lean manufacturing towards sustainable development. Sustainability, 13(1), 96. google scholar
  • Tripathi, D., Patnaik, B., Sarkar, B., & Srivastava, R. K. (2023). Lean, green, and smart manufacturing: An ingenious framework for enhancing the sustainability of operations management on the shop floor in industry 4.0. Computers & Operations Research, 138, 105276. google scholar
  • Trevino-Elizondo, R., Duran-Rivero, M., & Cantu-del Ângel, D. (2023). A Maturity Model to Become a Smart Organization Based on Lean and Industry 4.0 Synergy. Sustainability, 15(5), 2251. google scholar
  • Tsai, Y. C., Tseng, Y. C., Lee, Y. F., Chou, Y. H., Chang, J. W., & Lai, F. J. (2021). Use of the smart lean method to conduct high-quality integrated perioperative management prior to hospitalization. Scientific Reports, 11(1), 20569. google scholar
There are 37 citations in total.

Details

Primary Language English
Subjects Industrial Engineering
Journal Section Research Article
Authors

Mehmet Akif Gündüz 0000-0002-3884-1409

Sercan Demir 0000-0003-0764-9083

Turan Paksoy 0000-0001-8051-8560

Early Pub Date March 22, 2024
Publication Date
Submission Date July 20, 2023
Acceptance Date December 8, 2023
Published in Issue Year 2024 Volume: 2024 Issue: Erken Görünüm

Cite

APA Gündüz, M. A., Demir, S., & Paksoy, T. (2024). Road-mapping for smart and lean tools with a sustainability perspective: A new model proposal. Journal of Transportation and Logistics, 2024(Erken Görünüm). https://doi.org/10.26650/JTL.2024.1329972
AMA Gündüz MA, Demir S, Paksoy T. Road-mapping for smart and lean tools with a sustainability perspective: A new model proposal. JTL. March 2024;2024(Erken Görünüm). doi:10.26650/JTL.2024.1329972
Chicago Gündüz, Mehmet Akif, Sercan Demir, and Turan Paksoy. “Road-Mapping for Smart and Lean Tools With a Sustainability Perspective: A New Model Proposal”. Journal of Transportation and Logistics 2024, no. Erken Görünüm (March 2024). https://doi.org/10.26650/JTL.2024.1329972.
EndNote Gündüz MA, Demir S, Paksoy T (March 1, 2024) Road-mapping for smart and lean tools with a sustainability perspective: A new model proposal. Journal of Transportation and Logistics 2024 Erken Görünüm
IEEE M. A. Gündüz, S. Demir, and T. Paksoy, “Road-mapping for smart and lean tools with a sustainability perspective: A new model proposal”, JTL, vol. 2024, no. Erken Görünüm, 2024, doi: 10.26650/JTL.2024.1329972.
ISNAD Gündüz, Mehmet Akif et al. “Road-Mapping for Smart and Lean Tools With a Sustainability Perspective: A New Model Proposal”. Journal of Transportation and Logistics 2024/Erken Görünüm (March 2024). https://doi.org/10.26650/JTL.2024.1329972.
JAMA Gündüz MA, Demir S, Paksoy T. Road-mapping for smart and lean tools with a sustainability perspective: A new model proposal. JTL. 2024;2024. doi:10.26650/JTL.2024.1329972.
MLA Gündüz, Mehmet Akif et al. “Road-Mapping for Smart and Lean Tools With a Sustainability Perspective: A New Model Proposal”. Journal of Transportation and Logistics, vol. 2024, no. Erken Görünüm, 2024, doi:10.26650/JTL.2024.1329972.
Vancouver Gündüz MA, Demir S, Paksoy T. Road-mapping for smart and lean tools with a sustainability perspective: A new model proposal. JTL. 2024;2024(Erken Görünüm).


The JTL is being published twice (in April and October of) a year, as an official international peer-reviewed journal of the School of Transportation and Logistics at Istanbul University.