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Chapter 2:- Literature review(2.5.

incomplete)
2.1. Current Trends on Lean Management A review
M. Shabeena Begam, R.Swamynathan, J.Sekkizhar
International Journal of Lean Thinking / Volume 4, Issue 2 (December 2013)

The primary aim of the study is to find out the needs and examine the
degree to which the concepts of lean management are put into practice
within various manufacturing Industry.
(i) This is an overview for finding the current situation of lean
management practices in
manufacturing industries.
(ii) It is a measure to identify the constrains that retains lean
manufacturing in the infant stage in manufacturing firms and helps to
identify the muda (waste) that evolves in an processing unit and gives out
supporting measures to remove the same.
The constraint that predict the implementation and sustainability of lean
manufacturing tools and techniques are also discussed.
This paper presented an important imminent into the status of lean
manufacturing implementation in manufacturing industries. The progress
in lean implementation is snail-paced and needs to be augmented. It has
a further scope to develop focused lean concepts, which could be
implemented in other kind of manufacturing environment like low volume,
high variety and high volume and low variety. The major reasons for the
low level of lean management were anxiety in changing the attitude of
workers, lack of awareness, and training about the lean management
concepts, cost and time involved in lean implementation. Therefore, it can
be concluded that the manufacturing industry needs to give more
attention to implement lean management in all the key areas.

2.2.Lean Manufacturing Tool and Techniques in


Process Industry
Sharma Neha, Matharou Gurpreet Singh, Kaur Simran, Gupta
Pramod
International Journal of Scientific Research and Reviews IJSRR 2013

The purpose of the paper is to highlight the lean principles, tools and
benefits of lean concepts in industries. Lean manufacturing is plethora of
principles that focus on cost reduction by identifying and eliminating non
value added activities. The fiercely globalised and competitive markets of
21st century demand for increasing high variety of products at reducing

cost, lesser lead time and perfect quality. It addresses the application of
lean manufacturing concepts to the continuous production/process sector
with a focus on the steel industry.
The current level of lean implementation in industries is examined. It also
showed that certain
techniques could work universally. It has been concluded that major
manufacturing industries have been trying to adopt manufacturing
initiatives in order to stay alive in the new competitive market place .Lean
manufacturing is one of these initiatives that focus on cost reduction by
identifying and eliminating on value added activities .

2.3. Seven wastes elimination targeted by lean


manufacturing case study gaza strip manufacturing
firms
Khalil A. El-Namrouty, Mohammed S. AbuShaaban
Dept of Economics and political Science, Al-Oma Univesity, Islamic University- Gaza, Palestinian National Authority
Paper published: 10/2012

This paper aims to investigate and analyze the current situation of wastes elimination of the manufacturing firms
in Gaza Strip and its important role for reducing the production cost; in addition it aims to promote lean thinking
through studying the seven wastes that are targeted by the lean manufacturing philosophy.
The main goal of the present research work is to investigate the current situation of wastes elimination in the
manufacturing firms in Gaza Strip and its important role for reducing the production cost. Also, it aims to
promote Lean thinking in Gaza Strip manufacturing firms, also, the research seeks to provide a comprehensive
picture of the reality of the wastes elimination management and its multiple dimensions in the manufacturing
firms and paving the way for officials to make steps and to develop policies to ensure the competition of the
Palestinian industry.
Wastes Relations Matrix (WRM) was implemented to analyze the effect of each waste on the other six wastes.
The main findings are that lean manufacturing (wastes elimination) affects positively on reducing the production
cost for the manufacturing business in Gaza strip.

2.4. ENHANCING LEAN MANUFACTURING USING THE VALUE STREAM MAPPING TOOL IN
PHARMACEUTICAL OPERATIONS : A CASE STUDY OF A PHARMACEUTICAL
MANUFACTURING COMPANY IN ZIMBABWE.
W. M. Goriwondo, A.F. van der Merwe, T. D. Makura Department of Industrial and Manufacturing
Engineering

National University of Science and Technology (Zimbabwe) 2013-12-11


Value Stream Mapping (VSM) is a lean manufacturing technique used to analyze and
improve value-addition. It emanates from developments on the Toyota Production System
(TPS) but with wide application outside the automotive industry. VSM helps identify and
eliminate waste in the service and production sectors.
The Pharmaceutical Industry is one that needs to uphold highest standards of performance
particularly those that improve product quality in line with improved safety and hygiene. The
company under study is a manufacturer and distributor of both pharmaceutical and
nonpharmaceutical products. This made it extremely difficult for manufacturing organizations
to perform, furthermore implement improvement initiatives. There were stock shortages for
raw materials that had a ripple effect towards meeting customer orders. Due to erratic
supplies of raw materials, productivity decreased while at the same time processes were

affected resulting in very low capacity utilization. it is imperative to use lean manufacturing
techniques to analyze the current state of activities and processes in order to make logical
explanations and develop solutions that are in line with World Class performance.
Srinivasan [8] explains Value Stream Mapping (VSM) as the process of mapping the material
and information flows for components and sub-assemblies in a value chain. It was also
defined by Rother and Shook [10] as a tool, which allows identified ways to get material and
information to flow without interruption, improve productivity and competitiveness, and help
people implement system rather than isolated process improvements. This paper details
application of VSM in the pharmaceutical sector using two product lines at a manufacturing
company. Results obtained show improvements in critical lean metrics. The Future State
Map (FSM) developed shows a lean operation that ensures harmonious flow of both
materials and information that was achieved through systematic elimination of waste.
The application of the Value Stream Mapping tool ensures that the approach is systematic
and results in total elimination of waste while improving on the major Lean Metrics.

2.5. Optimizing an inventory control system in an Iranian large


company, a case study
M. Tabari, T. Mojibi
This paper addresses an inventory control system in an Iranian large company, Mazandaran Wood
and Paper Industries (MWPI). By optimizing the current system, we find the ordering and holding
costs resulting in a reduction of the total inventory cost. We calculate the economic order quantity
(EOQ) and re-order point (ROP). As a sample, six items of raw materials are taken into account,
which are considered about 94% of the total inventory in the warehouse. The results of the study show
that the total cost is reduced by 41% in the optimized inventory control system.

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2.6. Inventory Management of Spare Parts by Combined FSN and


VED (CFSNVED) Analysis
Vaisakh P. S., Dileeplal J., V. Narayanan Unni

International Journal of Engineering and Innovative Technology (IJEIT) Volume


2, Issue 7, January 2013

Inventory management is the process of efficiently overseeing the constant flow of units into and out
of an existing inventory. Inventory management of spare parts plays an important role in achieving the
desired plant availability at an optimum cost. It presents a spare part classification method based on
item movement in store department and criticality. FSN analysis is used to find out the fast moving,
slow moving, and non-moving items in a store department and VED analysis is applied to non-

moving items. Combined FSN and VED analysis is carried out to find the non-moving items which
are less critical.
In a continuous chemical process industry there are nearly 40,000 inventory items including raw
materials, spare parts and work in process inventory. These inventories need a proper inventory
control system for minimizing the cost. On analysis of these, it is found that there is scope of
improvement in the inventory management.
Several methodologies have been adopted for inventory management of spare parts. FSN analysis is
used to find out the non-moving items in store department and VED analysis is performed to classify
non-moving items based on their criticality. Higher the stay of item in the inventory, the slower would
be the movement of the material.
It shows that there are lot of spare parts which comes under non-moving category resulting in higher
inventory cost. Higher inventory cost is mainly due to higher storage cost and inventory holding cost.
Non-moving items need to be controlled in order to reduce inventory cost. A VED analysis is
performed on the non-moving items, which are identified by the FSN analysis. The non-moving items
are classified in to vital (NV), essential (NE) and desirable (ND) items based on the criticality rate.
Combined FSN and VED analysis shows that out of the 44 non-moving items, 26 items are of
desirable category. ND items are less critical and their unavailability will not affect the production
process. These ND items cause higher inventory holding cost at stores department and reducing the
space availability as they are non-moving. So avoiding or eliminating the ND class items will
increase the space availability and reduce inventory holding cost, which in turn helps to attain
industry wide standard.

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