A Virtual Learning Tool Design Using Lean Principles

A virtual learning tool that allows users to explore and learn the basic principle of warehousing operations using an avatar is described in this chapter. Several steps are utilized during the conception and the design phase of the application to ensure a well-built quality system. An analysis of a commonly used Lean Six Sigma principle such as the Plan-Do-Check-Act is presented to show its impacts on the conception and design of the virtual warehousing operation environments. Also, other lean principles are infused in the design of the system to ensure its user-friendliness through the use of regular tasks in an online learning environment. The use of the Plan-Do-Check-Act in the design process ensures an increased efficiency, improved quality, and better experience to potential users of the simulated warehousing operations.

Single-Minute Exchange of Dies at a Kaizen Event

Lean concepts play a fundamental role in the promotion of continuous improvement in the workplace. This chapter seeks to assess the impact of Kaizen events on an organization's bottom line, in the case of Single-Minute Exchange of Dies (SMED) that is a system for dramatically reducing the time it takes to complete equipment changeovers. In this case study, SMED was used in combination with other lean tools such as 5S and standardized work in a bid to promote continuous improvement of the “flawed” operations that occur in a world-class manufacturer plant. This analysis is critical in determining whether the path to achieving continuous improvement process for the team in the organization can be achieved through the use of SMED. The results have shown that a lean strategy like SMED, coupled with other lean strategies like 5s and TPM, plays a fundamental role in reducing process inefficiencies in the plant.

Dell's Just-in-Time Model in West Africa

Dell Computer Corporation founded by Michael Dell started in 1985 and has become the world's leading computer systems company today. Dell's motto is simple: to design, build, and customize products and services to satisfy a range of customer requirements. A few years after introducing its next-day on-site service, which will become the company core of its competitive edge, Dell started to expand internationally with the opening of many subsidiaries. This chapter assesses the feasibility of implementing Dell's model and its impacts on a third-world economies such as Ghana. Key factors such as the Ghana natural and human resources are assessed. The findings show that certain attributes must be in place to facilitate the JIT business model, especially when looking at emerging markets like Ghana with a clue on what it takes to implement the business model application in manufacturing, service, or production settings.

Lean and Total Quality Management in Civil Engineering

The aim of this chapter is to examine the utilization of total quality management (TQM), ISO 9000, and Lean concepts in the management processes of civil engineering consulting firms. The history of management theory and the existing literature related to total quality management, ISO 9000, and Lean concepts as applied to the civil engineering profession were reviewed. Also, the practical application of these concepts in civil engineering firms' operations and the extent that academic courses in these topics are offered were analyzed. The study is based on internet research and interviews with civil engineering managers and college professors. The results show that while the literature strongly endorses the utilization of these management concepts, the actual use is little known in the professional business of civil engineering. Also, in general, undergraduate civil engineering academic programs in the United States do not offer specific courses, which cover these concepts in their curriculums.

Reducing Hospital Costs by Reducing Supply Waste

Hospitals lose a large amount of money through waste as defined by lean. Processes have been in place many years at medical facilities and waste is often accepted as unavoidable in the rightful “patient first” mentality. The Plan, Do, Check, Act cycle is used for the control and continual improvement of the waste management process at the hospital where the study took place. By adapting and utilizing lean and statistical tools such as scatter diagrams, histograms, Pareto charts, fishbone diagrams, and control charts, waste can be identified and reduced or eliminated. The use of the statistical tools provides a visual presentation of the message that the team conveyed. They are especially useful to summarize the information that would normally require much time and effort to elucidate its complexity. Further, they provide a visual summation with still a great deal of details leading to increased satisfaction, efficiency, and creates competitive advantage.

Lean Tools to Evaluate Lighting Conditions

Lighting in indoor and outdoor settings has a purpose of providing an environment that is deemed as being comfortable and safe with the highest amount of light at the lowest possible consumption of energy. On the downside, there are instances where lighting is not as efficient as it is expected to be. For instance, the current outdoor lighting infrastructure at the University Campus (Referred to as “Campus”) located in a southern town in the United States of America proves this fact. In reality, the lighting on this campus is outdated when compared to the expected lighting standards. The main objective of the chapter is to use lean tools to analyze data on the light luminosity, pole locations, and other conditions. The results suggest a recommendation for a lean solution for the implementation of new and additional lighting on the Campus, which is deemed to provide efficiency and safety.

Lean Process Improvement for Rework Performance in Manufacturing

The primary purpose of this chapter is to identify the factors in the process for performance rework that are causing the most cost to a local manufacturing company to reduce the cost and improve the process. The data comes directly from the facility as historical data from the year 2016. The authors also collected data on low band and high band noise defects. The first method is the value stream map, current state map, and future state map. The second method is to measure noise levels of the bearings using the Anderon meter and Waveometer. The third method is to construct control charts using Minitab software. The findings demonstrated that bearings that fail due to low band noise produce a low final yield after being reworked. On the other hand, bearings that fail due to high band noise had a much higher final yield after being reworked.