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A waste relationship model and center point tracking metric for lean manufacturing systems

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  • Sainath Gopinath
  • Theodor Freiheit

Abstract

Lean manufacturing is about eliminating waste, which requires the creation of waste metrics that are tracked in order to create the conditions for its elimination. In this article, metrics used to monitor the seven traditional non-value adding wastes types of overproduction, defects, transportation, waiting, inventory, motion, and processing are explored and a “center point metric pair” is proposed that can give systematic insight into system waste performance and trade-offs. For example, lower work-in-process levels (inventory waste) may require more replenishment (transportation waste) in order to maintain production. A waste relationship model is proposed that can be used to derive the relationship between different wastes in a Pareto-optimal waste-dependent lean system. The trade-off relationships are statistically verified using simulation experiments across different system configurations, complexities, and planning scenarios.

Suggested Citation

  • Sainath Gopinath & Theodor Freiheit, 2012. "A waste relationship model and center point tracking metric for lean manufacturing systems," IISE Transactions, Taylor & Francis Journals, vol. 44(2), pages 136-154.
    • Handle: RePEc:taf:uiiexx:v:44:y:2012:i:2:p:136-154
    DOI: 10.1080/0740817X.2011.593609
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    Cited by:

    1. Soliman, Marlon & Saurin, Tarcisio Abreu & Anzanello, Michel Jose, 2018. "The impacts of lean production on the complexity of socio-technical systems," International Journal of Production Economics, Elsevier, vol. 197(C), pages 342-357.
    2. Carolina Cruz Villazón & Leonardo Sastoque Pinilla & José Ramón Otegi Olaso & Nerea Toledo Gandarias & Norberto López de Lacalle, 2020. "Identification of Key Performance Indicators in Project-Based Organisations through the Lean Approach," Sustainability, MDPI, vol. 12(15), pages 1-19, July.
    3. Jagdish Bhadu & Pramod Kumar & Jaiprakash Bhamu & Dharmendra Singh, 2022. "Lean production performance indicators for medium and small manufacturing enterprises: modelling through analytical hierarchy process," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 13(2), pages 978-997, April.
    4. Lakhan Patidar & Vimlesh Kumar Soni & Pradeep Kumar Soni, 2017. "Manufacturing wastes analysis in lean environment: an integrated ISM-fuzzy MICMAC approach," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 8(2), pages 1783-1809, November.

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