IDEAS home Printed from https://ideas.repec.org/a/gam/jsusta/v14y2022i17p11020-d906074.html
   My bibliography  Save this article

Lean Six Sigma with Value Stream Mapping in Industry 4.0 for Human-Centered Workstation Design

Author

Listed:
  • Fu-Kwun Wang

    (Department of Industrial Management, National Taiwan University of Science and Technology, Taipei City 106335, Taiwan)

  • Benedictus Rahardjo

    (Department of Industrial Management, National Taiwan University of Science and Technology, Taipei City 106335, Taiwan)

  • Pol Rifa Rovira

    (Thermo King Ireland Limited, D02 Dh60 Dublin, Ireland)

Abstract

Many industries have successfully implemented the define-measure-analyze-improve-control (DMAIC) method of Lean Six Sigma to improve their production activities. Value stream mapping (VSM) for Industry 4.0 allows us to understand the current state of operations in order to plan future improvements. In this study, we propose an improvement model based on DMAIC with VSM 4.0 for a truck cooler manufacturer to improve the picking workstation design with a human-centered approach. We use the DMAIC method to analyze the project step by step. After identifying the root cause, we identified countermeasures to improve the productivity. To reduce human error, the project team adopted a human-centered approach and applied lean tools, such as visual management, error prevention, and waste analysis. As a result of this case study, the yield rate was improved from 98% to 100%, and the direct savings of the project amounted to EUR 3180, mainly due to the freeing up of space. A human-centered LSS framework is also presented as a novel contribution of this study.

Suggested Citation

  • Fu-Kwun Wang & Benedictus Rahardjo & Pol Rifa Rovira, 2022. "Lean Six Sigma with Value Stream Mapping in Industry 4.0 for Human-Centered Workstation Design," Sustainability, MDPI, vol. 14(17), pages 1-19, September.
  • Handle: RePEc:gam:jsusta:v:14:y:2022:i:17:p:11020-:d:906074
    as

    Download full text from publisher

    File URL: https://www.mdpi.com/2071-1050/14/17/11020/pdf
    Download Restriction: no

    File URL: https://www.mdpi.com/2071-1050/14/17/11020/
    Download Restriction: no
    ---><---

    References listed on IDEAS

    as
    1. Naga Vamsi Krishna Jasti & Rambabu Kodali, 2015. "Lean production: literature review and trends," International Journal of Production Research, Taylor & Francis Journals, vol. 53(3), pages 867-885, February.
    2. Lea Hannola & Alexander Richter & Shahper Richter & Alexander Stocker, 2018. "Empowering production workers with digitally facilitated knowledge processes – a conceptual framework," International Journal of Production Research, Taylor & Francis Journals, vol. 56(14), pages 4729-4743, July.
    3. Carla M. A. Pinto & Jorge Mendonça & Lurdes Babo & Francisco J. G. Silva & José L. R. Fernandes, 2022. "Analyzing the Implementation of Lean Methodologies and Practices in the Portuguese Industry: A Survey," Sustainability, MDPI, vol. 14(3), pages 1-24, February.
    Full references (including those not matched with items on IDEAS)

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Catherine Maware & David M. Parsley, 2022. "The Challenges of Lean Transformation and Implementation in the Manufacturing Sector," Sustainability, MDPI, vol. 14(10), pages 1-24, May.
    2. Eleanor Smith & Kenneth McRae & Gordon Semple & Hugh Welsh & Dorothy Evans & Paul Blackwell, 2021. "Enhancing Vocational Training in the Post-COVID Era through Mobile Mixed Reality," Sustainability, MDPI, vol. 13(11), pages 1-17, May.
    3. Geandra Alves Queiroz & Paulo Nocera Alves Junior & Isotilia Costa Melo, 2022. "Digitalization as an Enabler to SMEs Implementing Lean-Green? A Systematic Review through the Topic Modelling Approach," Sustainability, MDPI, vol. 14(21), pages 1-21, October.
    4. Diana Chronéer & Peter Wallström, 2016. "Exploring Waste and Value in a Lean Context," International Journal of Business and Management, Canadian Center of Science and Education, vol. 11(10), pages 282-282, September.
    5. Ghobadian, Abby & Talavera, Irene & Bhattacharya, Arijit & Kumar, Vikas & Garza-Reyes, Jose Arturo & O'Regan, Nicholas, 2020. "Examining legitimatisation of additive manufacturing in the interplay between innovation, lean manufacturing and sustainability," International Journal of Production Economics, Elsevier, vol. 219(C), pages 457-468.
    6. Shahsavar, Aria & Sadeghi, J. Kiarash & Shockley, Jeff & Ojha, Divesh, 2021. "On the relationship between lean scheduling and economic performance in shipbuilding: A proposed model and comparative evaluation," International Journal of Production Economics, Elsevier, vol. 239(C).
    7. Sandra Brosnan & David O’Donnell & Philip O’Regan, 2019. "A performative exploration of the lifeworlds of human capital and financial capital: an intellectual capital case vignette," Journal of Management & Governance, Springer;Accademia Italiana di Economia Aziendale (AIDEA), vol. 23(2), pages 321-344, June.
    8. Rohit Kumar Singh & Sachin Modgil, 2023. "Assessment of Lean Supply Chain Practices in Indian Automotive Industry," Global Business Review, International Management Institute, vol. 24(1), pages 68-105, February.
    9. Andreas Felsberger & Gerald Reiner, 2020. "Sustainable Industry 4.0 in Production and Operations Management: A Systematic Literature Review," Sustainability, MDPI, vol. 12(19), pages 1-39, September.
    10. Liu, Fuzhen & He, Chaocheng & Lai, Kee-hung, 2024. "Incorporating resource responsibility into production and logistics management: An empirical investigation," Transportation Research Part E: Logistics and Transportation Review, Elsevier, vol. 187(C).
    11. David Ferreira & Pedro Cunha, 2022. "Ranking Critical Tools in the Implementation of Lean Six Sigma as an Integrated Management System in Portugal," Papers 2212.00088, arXiv.org.
    12. Genc, Talat S. & De Giovanni, Pietro, 2020. "Closed-loop supply chain games with innovation-led lean programs and sustainability," International Journal of Production Economics, Elsevier, vol. 219(C), pages 440-456.
    13. Hao Wang & Xiaoxia Zhang & Hui Yuan & Zhiguang Wu & Ming Zhou, 2023. "A Lean Scheduling Framework for Underground Mines Based on Short Interval Control," Sustainability, MDPI, vol. 15(12), pages 1-17, June.
    14. Liu, Fuzhen & He, Chaocheng & Lai, Kee-hung, 2024. "Market reaction to responsible production practices adoption: The role of firm size and financial slack," International Journal of Production Economics, Elsevier, vol. 272(C).
    15. Brad Stelian & Brad Emilia, 2015. "Lean Innovation of Course Unit Contents," Balkan Region Conference on Engineering and Business Education, Sciendo, vol. 1(1), pages 1-9, November.
    16. Hardcopf, Rick & Liu, Gensheng (Jason) & Shah, Rachna, 2021. "Lean production and operational performance: The influence of organizational culture," International Journal of Production Economics, Elsevier, vol. 235(C).
    17. Geng, D. & Evans, S. & Kishita, Y., 2023. "The identification and classification of energy waste for efficient energy supervision in manufacturing factories," Renewable and Sustainable Energy Reviews, Elsevier, vol. 182(C).
    18. Pearce, Antony & Pons, Dirk & Neitzert, Thomas, 2018. "Implementing lean—Outcomes from SME case studies," Operations Research Perspectives, Elsevier, vol. 5(C), pages 94-104.
    19. Möldner, Alexander Kurt & Garza-Reyes, Jose Arturo & Kumar, Vikas, 2020. "Exploring lean manufacturing practices' influence on process innovation performance," Journal of Business Research, Elsevier, vol. 106(C), pages 233-249.
    20. Pearce, Antony & Pons, Dirk, 2019. "Advancing lean management: The missing quantitative approach," Operations Research Perspectives, Elsevier, vol. 6(C).

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:gam:jsusta:v:14:y:2022:i:17:p:11020-:d:906074. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: MDPI Indexing Manager (email available below). General contact details of provider: https://www.mdpi.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.