Lean Manufacturing: Implementation, Opportunities and Challenges



Series: Manufacturing Technology Research
BISAC: TEC020000

The paradigm of manufacturing is undergoing a major evolution throughout the world. The use of computers, the Internet and new challenges related to the Industry 4.0 have changed the way we engineer and manufacture products. Improving production with Lean Thinking is an evolution of a traditional approach in order to improve its processes to remain competitive in the global market.

Lean Manufacturing is a multidimensional approach that embraces a wide variety of management practices in a unified system. These practices contain, quality systems, team work, and supplier management, among others. Nowadays, other practices have been adopted such as human factors and ergonomics.

This book presents contributions of Lean Manufacturing applications in the world development and is intended to provide a comprehensive view of issues related to this area, with a specific focus on lean engineering principles; it is full of practical production examples of how Lean Thinking can be applied effectively to production systems.

This work was conceptualized for an audience of graduate students mainly; however, it can also be consulted by engineers and company managers who seek state-of-the-art applications on Lean Manufacturing within a wide diversity of scenarios and conditions.

The book, organized into 17 chapters, is intended to be an excellent source for dissemination of applied researches, lean concepts, and practices that have been successfully applied in the developing world domain. The book is also an excellent example of academy purpose with collaboration between different institutions from different countries that provide a global approach.

Maria João Viamonte, PhD
ISEP’s President
(Imprint: Nova)

Table of Contents

Table of Contents


Chapter 1. Lean Thinking across the Company: Successful Cases in the Manufacturing Industry
(Rui Borges Lopes, Leonor Teixeira and Carlos Ferreira, Department of Economics, Management, Industrial Engineering and Tourism [DEGEIT], Center for Research & Development in Mathematics and Applications (CIDMA), University of Aveiro, Aveiro, Portugal, and others)

Chapter 2. From the Factory Floor to New Product Development: Development and Implementation of a Lean Assessment Tool
(T. Welo, NTNU – Department of Mechanical and Industrial Engineering, Norway)

Chapter 3. Benefits and Challenges of Lean Manufacturing in Make-To-Order Systems
(Oladipupo Olaitan, Anna Rotondo, John Geraghty and Paul Young, Enterprise Process Research Centre,
School of Mechanical and Manufacturing Engineering, Dublin City University, Dublin, Ireland, and others)

Chapter 4. Sustaining Lean in Organizations through the Management of Tensions and Paradoxes
(Malek Maalouf, Peter Hasle, Jan Vang and Imranul Hoque, Department of Materials and Production, Aalborg University, Denmark, and others)
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Chapter 5. The Impact of 5S+1S Methodology on Occupational Health and Safety
(Joana P. R. Fernandes, Radu Godina, Carina M. O. Pimentel and João C. O. Matias, Department of Economics, Management, Industrial Engineering and Tourism [DEGEIT], University of Aveiro, Aveiro, Portugal, and others)

Chapter 6. Value of Real-Time Data for Cycle Time Optimisation at Wet Tools
(A. Rotondo, J. Geraghty and P. S. Young, Irish Manufacturing Research, and others)

Chapter 7. The Eighth Waste: Non-Utilized Talent
(M. Brito, A. L. Ramos, P. Carneiro and M. A. Gonçalves, Department of Mechanical Engineering, ISEP – School of Engineering, Polytechnic of Porto, Porto, Portugal, and others)

Chapter 8. Quality and Safety Continuous Improvement through Lean Tools
(Gilberto Santos, J. C. Sá, J. Oliveira, Delfina G. Ramos and C. Ferreira, Design School, Polytechnique Institute Cavado Ave, Portugal, and others)

Chapter 9. Lean Manufacturing Applied to the Production and Assembly Lines of Complex Automotive Parts
(Conceição Rosa, Francisco J. G. Silva, Luís Pinto Ferreira and J. C. Sá, DME – Department of Mechanical Engineering, ISEP – School of Engineering, Polytechnic of Porto, Porto, Portugal, and others)

Chapter 10. SMED Applied to Composed Cork Stoppers
(Eduardo Sousa, F. J. G. Silva, Carina M. O. Pimentel and Luís Pinto Ferreira, DME – Department of Mechanical Engineering, ISEP – School of Engineering, Polytechnic of Porto, Porto, Portugal, and others)

Chapter 11. Lean Production in the Portuguese Textile and Clothing Industry: The Extent of Its Implementation and Role
(Laura Costa Maia, Anabela Carvalho Alves and Celina Pinto Leão, R&D Centro ALGORITMI, Department of Production and Systems, School of Engineering, University of Minho, Guimarães, Portugal, and others)

Chapter 12. Lean Manufacturing Applied to a Complex Electronic Assembly Line
(F. J. G. Silva, Andresa Baptista, Gustavo Pinto and Damásio Correia, Mechanical Engineering Department, School of Engineering – Polytechnic of Porto [ISEP], Porto, Portugal, and others)

Chapter 13. Karakuri: The Application of Lean Thinking in Low-Cost Automation
(Stephanie D. Nascimento, Milena B. Alves, Julia O. Morais, Laryssa C. Carvalho, Robson F. Lima, Ricardo R. Alves and Robisom D. Calado, LabDGE – Laboratório Design Thinking Gestão e Engenharia Industrial, School of Production Engineering, Federal Fluminense University [UFF], Brazil, and others)

Chapter 14. Lean and Ergonomics: How to Increase the Productivity Improving the Wellbeing of the Workers – A Case Study
(J. Santos, F. J. G. Silva, G. Pinto and A. Baptista, DME – Department of Mechanical Engineering, ISEP – School of Engineering, Polytechnic of Porto, Porto, Portugal, and others)

Chapter 15. Measurement of the Level of Implementation of Sociotechnical and Ergonomic Practices and Lean Production Practices: Considerations from a Systematic Review Process
(E. P. Ferreira, J. Schmitt, L. G. L. Vergara, D. F. de Andrade and G. L. Tortorella, UFSC – Universidade Federal de Santa Catarina, Brazil)

Chapter 16. Lean Manufacturing and Industry 4.0: Facing New Challenges from a Shop-Floor Perspective
(Antonio Sartal and Helena Navas, University of Vigo, Spain, and others)

Chapter 17. Lean Healthcare in a Cancer Chemotherapy Unit: Implementation and Results
(T. M. Bertani, A. F. Rentes, M. Godinho Filho and R. Mardegan, EESC – University of São Paulo, Brazil, and others)



“This book deals with a hot topic and it is extremely useful for understanding integrated production management processes as well as solving the new challenges of industry 4.0.” – Professor Anónio Bastos Pereira, University of Aveiro, Portugal

Keywords: Lean manufacturing, Processes optimization, Six Sigma, Single Minute Exchange of Die, Ergonomics, 5S, Keizen, Line Balancing, Lean Line Design, Value Stream Mapping

This book has been written for scholars, MSc and PhD students, people managing SMEs companies, Industrial managers, Companies owners, people interested in industrial management, people interested in production optimization, people related to industrial processes, end so on.

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