Lean Systems

In this publication, IR4TD researchers investigate the transition of a Lean Manufacturing professional course from in-person to online synchronous learning at a large U.S. university. Prompted by the COVID-19 pandemic, the study compares the performance of 212 in-person and 43 online participants, focusing on three competencies: Lean culture, problem-solving, and Lean systems. The results showed no significant difference in performance between in-person and online participants in Lean systems and problem-solving. However, online participants performed better in Lean culture. The study highlighted the positive feedback from participants about the online program's structure and organization, noting that online learning could successfully replicate in-person training outcomes. Best practices for transitioning in-person engineering programs to online formats are suggested, emphasizing the importance of interactive and well-organized synchronous sessions. The paper contributes valuable insights into the effectiveness and challenges of converting lab-based continuing education programs into online formats, particularly for adult industry professionals.

Dr. Maware and Dr. Parsley explore the obstacles faced by North American manufacturing organizations in adopting and sustaining Lean Manufacturing (LM). Lean principles, known for improving efficiency, reducing waste, and enhancing productivity, often face barriers in practical implementation. Using a survey from 50 manufacturing companies, the study identifies key challenges, including resistance to change, lack of proper training, and inadequate management support. A major finding is that cultural resistance within organizations, especially the need for a shift in leadership and employee mindset, is the most significant barrier to sustaining Lean. Technical difficulties such as poor data collection, non-standardized processes, and inadequate key performance indicators (KPIs) are also highlighted. The study applies fuzzy analytic hierarchy process (FAHP) and fuzzy analytic network process (FANP) to prioritize these challenges. Recommendations focus on addressing cultural barriers and improving management support to create a sustainable Lean environment. The research emphasizes the importance of leadership in fostering a Lean culture and investing in proper training to overcome technical and operational hurdles.

Besides our Lean Systems research focus, our Lean Systems group offers various services to organizations through TRUE LEAN. True Lean serves businesses at all professional levels, from executives and management to entry-level engineers and technicians.