Lean Systems

As global markets become increasingly competitive and complex, the need for lean production systems to enhance efficiency, reduce waste, and boost productivity continues to grow. At IR4TD, our research is dedicated to helping organizations across industries apply lean principles to create innovative strategies that empower leaders to meet these challenges with streamlined, sustainable processes, delivering maximum value to their customers. Our research focuses on critical areas that enhance lean transformation, blending structured problem-solving methodologies with the power of digital technologies (Industry 4.0). We analyze manufacturing systems to identify opportunities for efficiency gains and develop lean solutions that can be applied across a range of industries. Whether it is managing the complexities of high variety/low volume production or overcoming the challenges of lean implementation, our work emphasizes practical strategies that drive continuous improvement and scalable growth.

At IR4TD, we go beyond theory by helping organizations apply lean techniques to their unique situations. Through data-driven analysis and real-world implementations, we guide our partners in achieving their current objectives while laying the groundwork for future growth. By leveraging digital tools, we create robust, scalable solutions that drive continuous improvement and foster a culture of innovation, providing a clear roadmap to transform operations for lasting success.

For more information, please contact us.

Our Lean Systems Research Highlights

Moving Lab-based In-person Training to Online Delivery: The Case of a Continuing Engineering Education Program

Journal of Computer Assisted Learning by by Catherine Maware, David M. Parsley, Kun Huang, Gerry M. Swan, and Nelson Akafuah

Collaborator: Department of Curriculum and Instruction, University of Kentucky

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.

The Challenges of Lean Transformation and Implementation in
the Manufacturing Sector

Sustainability (2022) by Catherine Maware and David Parsley

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.

Other Lean Systems Papers

1. Examining the Progress in Additive Manufacturing in Supporting Lean, Green and Sustainable Manufacturing: A Systematic Review in Applied Sciences (2024) by Catherine Maware, Rumbidzai Muvunzi, Tinotenda Machingura, and IIsesan Daniyan

Collaborator: Department of Industrial & Systems Engineering, Cape Peninsula University of Technology, South Africa; Department of Industrial & Systems Engineering, University of Pretoria, South Africa; and Department of Mechanical & Mechatronics Engineering, Achievers University, Nigeria

2. Can Industry 4.0 Assist Lean Manufacturing in Attaining Sustainability over Time? Evidence from the US Organizations in Sustainability (2023) by Catherine Maware and David Parsley

3. Challenges to Lean Implementation from a True Lean Toyota Production System Perspective in The Cambridge International Handbook of Lean Production (2021) by Michael Abbot Maginnis, William R. Cooper, and David Parsley

4. The model area in successful lean transformation and scale modeling in Progress in Scale Modeling (2020) by Willam Cooper, Michael Abbot Maginnis, David Parsley, and Kozo Saito

5. REGRESSION ANALYSIS OF FACTORS IMPACTING PROBLEM-SOLVING ENGAGEMENT WITHIN LEAN SYSTEMS IMPLEMENTATION, A Doctoral Dissertation (2018) by David Parsley

For more research output on Lean Systems, please visit Scholars@UK.

UK - True Lean

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.

True Lean Highlight Services

Lean Certification Series

Based upon proven Toyota practices, combined with UK program experience with many organizations, this series provides participants with the knowledge & skills necessary to navigate through your True Lean transformation, ensuring long-term sustainability.

More Information on Lean Certification Series

Lean Executive Leadership Institute

Executives learn the critical transferable elements of The Toyota Way and TPS to develop a common understanding and alignment (One Voice) among the leadership as an organization begins its drive to True Lean.

More Information about Lean Executive Leadership Institute

Eight-Step Problem Solving

Systematic problem-solving is a core element of a True Lean™ organization. This course teaches the 8-Step problem-solving method used within Toyota at all levels and functions to practice effective continuous learning and improvement.

More Information about Eight-Step Problem Solving

Executive Coaching

Working with experienced True Lean practitioners, executives learn how to start or build upon their organization’s True Lean journey by focusing on developing a strategy and plan that is aligned around a clear One Voice.

More Information about Executive Coaching