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Purpose: This research aims to implement Lean Manufacturing (LM) techniques and tools (T&T) in a retail distribution center located in Mariano Roque Alonso, Paraguay, targeting waste reduction and efficiency improvements in fresh and frozen product (FFP) handling to reduce long lead times.Design/methodology/approach: This study was conducted in two phases. First, a literature review revealed the key gaps to be addressed, the most commonly faced problems, and the LM tools applicable to solving these issues. Second, a case study was conducted in which LM T&T were applied to reduce the long lead time and propose solutions to address difficulties in the FFP process. Five problem-detection tools (flowchart, brainstorming, Ishikawa diagram, Pareto, and value stream mapping) and three improvement tools (kaizen, 5S, and Plan-Do-Check-Act) were applied to streamline FFP process from order generation to store reception.Findings: The analysis revealed significant inefficiencies: four were workforce-related, ten related to work methods, six environmental, and three product-related. Addressing these issues could substantially reduce operational bottlenecks and improve process throughput.Practical implications: The application of LM techniques significantly minimized waste, enhancing time management and human resource utilization, which led to a 96% improvement in FFP processing efficiency. These changes are expected to shorten lead times, bolster competitive advantage, and increase customer satisfaction.Originality/value: This study underscores the versatility of LM techniques, adapting them from manufacturing to retail distribution. The innovative combination of kaizen with 5S and PDCA offers a robust framework for ongoing improvements, promising for broader adoption in the retail sector.

Regional geochemical mapping was carried out in Bilaspur and Korba Districts of Chhattisgarh, and stream sediments/slope wash, soil, and water samples were analyzed for concentration of heavy metals. The study contributes to understanding heavy metals contamination of sediments, soils, and water due to anthropogenic activity, mainly in agriculture-based rural areas. The study reveals that high geochemical anomalies observed for heavy metals like Ni, Cr, As, and Zn in sediments and soil samples are due to the extensive uses of phosphatic fertilizer and soil amendments in the form of poultry and swine manure. Water quality assessment of major streams in the study areas shows that the water is suitable for domestic and agricultural uses. Correlation analysis reveals that the chemical weathering of rock-forming minerals doesn’t control the surface water chemistry of the study area and is also an anthropogenic source of sodium in water. This study also shows the importance of the country’s geochemical mapping database, which will have much broader applications than conventional mineral exploration and geological mapping.

Purpose: Identifying possible ergonomic risks generated by the implementation of Lean Manufacturing in organizations. Shows a need to integrate ergonomics and productivity indicators in process analysis, thus giving place to the ErgoVSM methodology, which is VSM (Value Stream Mapping) complemented with ergonomic analysis. Design/methodology/approach: This literature review aims to refer to the methodology and instruments used for its application, as well as the benefits obtained and the challenges that arise when applying it. Findings: This article presents a review of 26 publications regarding the ErgoVSM methodology. The ErgoVSM is mainly based on the VSM methodology developed by Rother & Shook that is most applied in the healthcare sector with ergonomic analysis instruments that focus on the physical and psychosocial factors of the workers. Originality/value: The review revealed that when using ErgoVSM, processes can be improved from the ergonomic perspective without negatively affecting productivity. Even though ErgoVSM requires more time for application compared to VSM, the value of the ergonomic data for decision making in process changes justifies the extra time.

ABSTRACT The growing need for solving the problem of food waste for tackling the survival of the planet and humankind is encouraging researchers to seek sustainable operations that alter the conventional methods that are currently in use in the food industry. Lean thinking has been used in this study to propose sustainable operations that incorporate social, economic, and environmental aspects and to handle the multidisciplinary and complex nature of reducing food waste. The value stream mapping methodology has been employed to explain food waste and generate drivers and to observe the end-to-end system flow. Since most of the waste is observed in upstream operations in emerging economies, one of the biggest meat-processing companies in Turkey is studied for illustrating the proposed methodology. As a result of the model, lean and sustainable food operations are suggested considering social, economic and environmental aspects. RESUMO A crescente necessidade de resolver o problema do desperdício de alimentos para a sobrevivência do planeta e da humanidade incentiva os pesquisadores a buscarem operações sustentáveis que alterem os métodos convencionais atualmente em uso na indústria de alimentos. Neste estudo, o pensamento enxuto foi utilizado para propor operações sustentáveis incorporando aspectos sociais, econômicos e ambientais e para lidar com a natureza multidisciplinar e complexa da redução do desperdício de alimentos. A metodologia de mapeamento do fluxo de valor foi empregada para explicar os fatores geradores de desperdício de alimentos e para ver o fluxo do sistema de ponta a ponta. Como a maioria dos resíduos pode ser observada em operações a montante em economias emergentes, a metodologia proposta é ilustrada em uma das maiores empresas de carne da Turquia. Como resultado do modelo, operações alimentares enxutas e sustentáveis foram sugeridas considerando aspectos sociais, econômicos e ambientais. RESUMEN La creciente necesidad de resolver el problema del desperdicio de alimentos para la supervivencia del planeta y la humanidad alienta a los investigadores a buscar operaciones sostenibles que alteren los métodos convencionales que se utilizan actualmente en la industria alimenticia. En este estudio, se ha utilizado la filosofía lean para proponer operaciones sostenibles que incorporen aspectos sociales, económicos y ambientales y para manejar la naturaleza multidisciplinaria y compleja de la reducción del desperdicio de alimentos. La metodología de mapeo de flujo de valor se ha empleado para explicar los generadores del desperdicio de alimentos y para ver el flujo del sistema de extremo a extremo. Dado que el mayor desperdicio se observa en las operaciones iniciales en las economías emergentes, se estudió una de las compañías de carne más grandes de Turquía para ilustrar la metodología propuesta. Como resultado del modelo, se han sugerido operaciones alimentarias magras y sostenibles que consideren aspectos sociales, económicos y ambientales.

Purpose The purpose of this study is to apply value stream mapping (VSM) in Malaysian pharmaceutical production warehouse. A current and future state value stream map from the raw material receiving end to the production unit was developed to find out waste and unwanted lead time. It was very much essential to cut down the supply chain lead time at the initial phase as the raw material unloading, sorting, temporary storage and dispatch to production were seen contributing to a huge lead time build-up. Design/methodology/approach The study was initiated with the selection of a product family, construction of the current state map, identification of various wastes and the development of future state map. Findings The expected outcomes of the study include the quantification of wastes, improvement in value-added percentage and lead time reduction. Research limitations/implications The study was carried out in a single pharmaceutical company. The results of the study are deployable and can be functional in similar production organizations. Contrary to common VSMs that capture core production processes, this study provides strong insights that shall help design lean supply chains, especially in the pharmaceutical domain. This paper has also addressed the viability of the lean in the pharmaceutical warehouse and the reduction in lead time to improve demand forecasting, marketing and sales. Practical implications The results of this study have indicated that a significant reduction in pharmaceutical warehouse supply chain lead time is possible as a result of the implementation of VSM from the supply chain’s perspective. Social implications The insights from this study help in understanding the pharmaceutical supply chain risks and their outcomes. Originality/value The paper reports a real-time study conducted in a warehouse of a pharmaceutical organization. Hence, the contributions are original.

Purpose: This paper presents an implementation of the Six Sigma DMAIC approach implementing lean tools and facilities layout techniques to reduce the occurrence of different types of nonconformities in the carpeting process. Such carpeting process can be found in several industries including construction, aviation, and automotive. Design/methodology/approach: The improvement process was built through a sequential implementation of appropriate interconnected tools at each phase of the DMAIC approach. Utilized tools included: Pareto analysis, control charts, Ishikawa chart, 5-Whys, failure mode and effect analysis, process capability ratio, value stream map, and strategic layout planning. Findings: The carpeting process capability, quality of the product, customer satisfaction, and cost of poor quality were significantly improved. Explicitly, the sigma level was improved from 2.297 to 2.886 and the defects per million opportunities was reduced from 21615 to 3905. Originality/value: This paper has demonstrated the coherent implementation of several quality tools, value stream map, and systematic layout planning within the DMAIC approach.

Purpose: This paper describes the use of simulation and case-study research to assess flexibility gains induced by the adoption of three Lean Manufacturing practices. Design/methodology/approach: We gather useful material and information about the manufacturing process of a selected Small-Medium Enterprise by adopting a case-research approach. The Value Stream Mapping is the method used for visualizing flows of products and information along the production system. Starting from the current arrangement of the company, computer simulation is used to assess the benefits arising from Cellular Manufacturing, Just-in-Time Delivery by Suppliers, and Single Minute Exchange of Dies. Findings: To investigate the flexibility improvements coming from the introduction of Lean Manufacturing, we present a simulation model of the described company on which we performed our analysis. We quantify the flexibility of different configurations according to the new 5-step approach in order to segregate the contribution of different lean techniques. Originality/value: We extend the combined use of Case Research and Computer Simulation to the research on Manufacturing Flexibility within Small-Medium Enterprises. We enhance the knowledge on this under investigated context collecting quantitative field data. Moreover, building on the factorial Design of Experiment, we introduce a new 5-step method to appraise the cost benefit ratio of lean techniques for flexibility. The managerial implication of this research is mostly related to the provision of a supporting method for the decision making process propaedeutic to Lean Manufacturing introduction.

Value stream mapping is a well-established tool for analyzing and optimizing value streams in production. In its conventional form, it requires a high level of manual effort and is often inefficient in volatile and high-variance environments. The idea of digitizing value stream mapping to increase efficiency has thus been put forward. A common means suggested for digitization is Process Mining, a field related to Data Science and Process Management. Furthermore, adding sustainability aspects to value stream mapping has also been subject to research. Regarding the ongoing climate crisis and companies' endeavors to improve overall sustainability, integrating sustainability into value stream mapping must be deemed equally relevant. This research paper provides an overview of the state of the art of Process Mining-based and sustainability-integrated value stream mapping, proposes a framework for a combined approach, and presents technical details for the implementation of such an approach, including a validation from practice.

With the emergence of Industry 4.0, digitalization and intelligent manufacturing are vital to ensure competitivity, especially for manufacturers reliant on legacy machines. Upgrading legacy machines with cyber physical technology under Industry 4.0 frameworks can enable connection of these machines to existing IoT networks to allow the sharing and exchange of production information. In this paper, a legacy machine used in sheet metal folding operations is upgraded by integrating switch sensors which provide detailed data on the machine status to stakeholders, enabling in-depth analysis of the production activity before and after the implementation of lean manufacturing methods. Furthermore, it is shown that the data collected can be applied to conduct dynamic value stream mapping (DVSM) in near real time to provide deeper level insight into manufacturing processes. More detailed mapping enables identification of wastes involved with labour and design. Therefore, an innovative graphical technique is proposed to improve the flattened pattern to reduce manual handling and ease bottlenecks identified by VSM. From the collected VSM data, a leanness measure was established to provide objective and quantitative evaluation of the process performance.