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Lean planning in the semi-process industry, a case study

Author

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  • Pool, Arnout
  • Wijngaard, Jacob
  • van der Zee, Durk-Jouke

Abstract

The lean approach is an idealizing improvement approach that has an enormous impact in the field of operations management. It started in the automotive industry and has since been widely applied in discrete manufacturing. However, extensions to the (semi-) process industry have been much slower. Resource characteristics of the (semi-) process industry obstruct a straightforward application. The notion of the point of discretization for the (semi-) process industry is helpful here. This notion builds on the fact that in most (semi-) process industries there is a point in production where process production turns into discrete production. Downstream of this point lean principles are applicable in a straightforward manner, while upstream lean needs to be interpreted in a more liberal way. In this article we address this issue by a case study. The study considers how the principles of 'flow' and 'pull' production - suggesting a regular, demand-driven product flow - may be implemented for the (semi-) process industry by introducing cyclic schedules. The conjectures guiding the case study are: (i) Cyclic schedules fit in a lean improvement approach for the semi-process industry, (ii) Cyclic schedules help to improve production quality and supply-chain coordination and (iii) Discrete event simulation is a useful tool in facilitating a participative design of a cyclic schedule. The case study is extensively described to be able to judge how the context of the changes and the intervention process contribute to the results of the intervention.

Suggested Citation

  • Pool, Arnout & Wijngaard, Jacob & van der Zee, Durk-Jouke, 2011. "Lean planning in the semi-process industry, a case study," International Journal of Production Economics, Elsevier, vol. 131(1), pages 194-203, May.
  • Handle: RePEc:eee:proeco:v:131:y:2011:i:1:p:194-203
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    References listed on IDEAS

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    1. De Smet, Rudi & Gelders, Ludo, 1998. "Using simulation to evaluate the introduction of a Kanban subsystem within an MRP-controlled manufacturing environment," International Journal of Production Economics, Elsevier, vol. 56(1), pages 111-122, September.
    2. Hüttmeir, Andreas & de Treville, Suzanne & van Ackere, Ann & Monnier, Léonard & Prenninger, Johann, 2009. "Trading off between heijunka and just-in-sequence," International Journal of Production Economics, Elsevier, vol. 118(2), pages 501-507, April.
    3. Abdulmalek, Fawaz A. & Rajgopal, Jayant, 2007. "Analyzing the benefits of lean manufacturing and value stream mapping via simulation: A process sector case study," International Journal of Production Economics, Elsevier, vol. 107(1), pages 223-236, May.
    4. van der Zee, D.J., 2006. "Modeling decision making and control in manufacturing simulation," International Journal of Production Economics, Elsevier, vol. 100(1), pages 155-167, March.
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    Cited by:

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    2. Germs, Remco & Foreest, Nicky D. van, 2014. "Optimal Control of Production-Inventory Systems with Constant and Compound Poisson Demand," Research Report 14001-OPERA, University of Groningen, Research Institute SOM (Systems, Organisations and Management).
    3. Opacic, Luke & Sowlati, Taraneh & Mobini, Mahdi, 2018. "Design and development of a simulation-based decision support tool to improve the production process at an engineered wood products mill," International Journal of Production Economics, Elsevier, vol. 199(C), pages 209-219.
    4. Noroozi, Sayeh & Wikner, Joakim, 2017. "Sales and operations planning in the process industry: A literature review," International Journal of Production Economics, Elsevier, vol. 188(C), pages 139-155.
    5. Sgarbossa, Fabio & Russo, Ivan, 2017. "A proactive model in sustainable food supply chain: Insight from a case study," International Journal of Production Economics, Elsevier, vol. 183(PB), pages 596-606.
    6. Tyagi, Satish & Choudhary, Alok & Cai, Xianming & Yang, Kai, 2015. "Value stream mapping to reduce the lead-time of a product development process," International Journal of Production Economics, Elsevier, vol. 160(C), pages 202-212.
    7. repec:dgr:rugsom:14001-opera is not listed on IDEAS

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