The practical relationship between continuous flow and lean construction in SMEs

Leanness assessment of a complex assembly line using integrated value stream mapping: a case study

Purpose

This paper proposes an integrated value stream mapping (VSM) for a complex assembly line to improve the leanness of a complex automotive component manufacturing organization.

Design/methodology/approach

This study depicts the application of VSM at the case organization, where top management is concerned about the challenges of higher cycle time and lower productivity. Gemba walks were conducted to establish the concept of “walk the flow, create the flow” along the assembly line. The multi-hierarchical cross-functional team developed the current value stream map to know the “as-is” state. Then, the team analysed the current VSM and proposed the future VSM for the “to-be” state.

Findings

The integrated VSM shows different processes and work cells, various wastes, non-value-added activities, cycle time, uptime and the material and information flows for both products of the assembly line on the same map. The integrated VSM reduced cycle time, non-value-added activities, work in process inventory and improved line efficiency and production per labour hour for both the products, simultaneously.

Research limitations/implications

The limitation of the study is that the study focussed only on the application of VSM for one complex assembly only. Future research may be conducted using the developed integrated VSM approach in other complex production environments.

Practical implications

Managers can identify and reduce system waste by incorporating the concept of integrated VSM in a complex production or assembly environment where two or more products are being manufactured/assembled with low similarity.

Originality/value

The application of VSM for assembly lines is highly challenging because of merging flows, a large number of child parts in the lines and assembly of more than one product on the same line.

Patterns emerging from the TQM paradigm in relation to the 21st century complex context within TQM journal

Purpose

The purpose of this research is to explore the deployment of the total quality management (TQM) paradigm in the TQM Journal in relation to the context of the 21st century. The study builds on the theoretical framework of the four quality paradigms that together compose TQM. The four paradigms differ in their effectiveness based on the context in which they are used. In a complex context, one would expect the reflective and the emergence paradigm to flourish. The TQM Journal is one of the leading scientific journals on TQM. If the assumption that the reflective and emergent paradigm would flourish in a complex environment is correct, one will see that represented in the past five years of scientific research in that magazine.

Design/methodology/approach

The TQM Journal articles of the past five years from January 2016 till January 2021 have been chosen as the scope of an exploratory review. The author assessed the title and abstract of all articles based on the characteristics of the four quality paradigms, as described in the theoretical framework. If the title and abstract did not provide enough data to take the decision for the assessment, the whole article has been taken into account. The results have been collated, summarized and reported. Based on the results, the author explores the possible patterns.

Findings

In total, 283 articles from 2016 to 2021 (from Volume 28, Issue 1 to Volume 33, Issue 1) were included in this study. In total, 45 were read fully to be able to characterize the article. Most of the studies relate the tertiary (33.3%) and secondary (27.9%) sectors. Healthcare was the sector in 32 of the cases (11.3%). Most studies have been conducted in Europe (n = 82, 28.9%) and Asia (n = 58, 20.5%). Within Europe, Italy was the most prolific country with, respectively, 25 (30.8%) of the articles. The USA and Canada only had five articles in these five years (1.8%). Many articles did not specify the region. More than half of the articles (52.4%) worked with surveys, questionnaires or other methods to involve the customer in the research; 16 articles (5.6%) used experts in the field through expert panels and such to collect data from. In total, 107 articles (37.8%) did involve no other stakeholders than the researchers themselves. Eight studies (2.8%) used action research or co-design methodology to create optimal stakeholder participation. Based on the data, four patterns can be discovered: the context sensitivity of the articles, reflexivity, coping with uncertainty and co-creation.

Research limitations/implications

It is acknowledged that the articles in the study were published in just one scientific journal. One can expect that this will be represented in other journals on TQM. Still, it would be interesting to conduct a follow-up study in other journals on TQM and compare the results. The research is done by one subjective researcher.

Practical implications

Research on TQM should take the complexity of the context into account. For that purpose, researchers should focus more on the emergence paradigm within TQM.

Originality/value

This study is the first to investigate TQM as a holistic paradigm, including the empirical, reflective, reference and emergence paradigm in TQM research.

Lean Management Framework for Healthcare Facilities Integrating BIM, BEPS and Big Data Analytics

An increase in the usage of information and communication technologies (ICT) and the Internet of Things (IoT) in Facility Management (FM) induces a huge data stack. Even though these data bring opportunities such as cost savings, time savings, increase in user comfort, space optimization, energy savings, inventory management, etc., these data sources cannot be managed and manipulated effectively to increase efficiency at the FM stage. In addition to data management issues, FM practices, or developed solutions, need to be supported with the implementation of lean management philosophy to reveal organizational and managerial wastes. In the literature, some researchers performed studies about awareness about building information modeling (BIM)-FM, and FM-related data management problems in terms of lean philosophy. However, the comprehensive solution for effective FM has not been investigated with the application of lean management philosophy yet. Therefore, this study aims to develop an FM framework for healthcare facilities by considering lean management philosophy since more stable workflow, continuous improvement, and creating more value to customers will help to deliver a more acceptable solution for the FM industry. Within this context, the integration of BIM, Building Energy Performance Simulations, and Big Data Analytics are proposed as a solution. In the study, the Design Science Research (DSR) methodology was followed to develop the FM framework. Depending on the DSR methodology, two scenarios were used to investigate the issue in a real healthcare facility and develop the FM framework. The developed framework was evaluated by four experts, and the revisions of the proposed framework were realized.