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Integration of green thinking into lean fundamentals by theory of inventive problems-solving tools
Abstract
Population of planet is growing constantly. According to United Nations official report of different projections there will be about 10 billion inhabitants on the Earth by 2050. Two out of three persons will live in the city. These facts force today's' manufacturers to find more innovative ways to satisfy future customers' needs from energy perspective and, on the other end, to take care of environment. Already today there is a certain need in set of specific rules for the companies to become more efficient and environment friendly at the same time. The combined approach of lean fundamental thinking with green manufacturing perspective analyzed with TRIZ (Theory of Inventive Problems-Solving) methodology is proposed in order to distinguish this target. The results are analyzed from Lean and Green wastes perspective on the basis of unified matrix. The main target of research is to create the short and clear guide for the manufacturers from where to start their way to innovative, environmental friendly and profitable manufacturing.
... Well-defined, documented and widely used standard methods and tools [38]. ...
... Although different tools, such as, LCA, DfE and EOL strategies are widely used, green practices are usually based on customised approaches [38]. ...
... In this line, there are the ones that propose to combine them into a new, single and stand-alone lean-green approach [47], while there are others that, based on the fact that lean practices are not only well-documented but also widely (and successfully) adopted all over the world, as well as that the lean culture do favour the implementation of green initiatives, propose to use an already stablished lean environment as a catalyst to the adoption and further incorporation of green practices [43,44,53]. Within the first group, waste management methods, like Waste Reducing Techniques (WRT), are the most used strategies to perform the combination [37,38,41,60]. In [53], a combined approach based on the Theory of Inventive Problems-Solving tools, is presented. ...
The current rapidly changing and highly competitive market has put companies under a great pressure towards adopting sustainable practices, in terms of keeping a healthy balance among economic, environmental and social performances. In this context, the lean-green manufacturing approach, which combines lean practices focused on customers’ demand, and green practices focused on reducing the business’ environmental impact, has gained popularity. Nevertheless, the lean-green manufacturing is still a relatively new practice, lacking a clear and structured research definition, and of significant evidence of successful cases in the practice. In this paper, a literature review is conducted to identify the actual possibility of combining lean and green practices, the current trends for implementing such combination and the potential sustainability improvements such implementation can lead. It is the authors’ intention that the findings analysed in this paper can contribute to the state-of-the-art of lean-green manufacturing and provide practitioners with a useful tool towards developing effective strategies for its deployment.
... The latest category is split into green transportation, green storage and distribution network design. When referring to the previous classification, the eleven articles are assigned to three different subcategories: 5 articles can be considered as contributing in green product design (part of topic #3) [24][25][26][27][28], 4 articles can be assigned to green production (design of the green production process) (part of topic #4) [29][30][31][32] and 2 articles to the design of the distribution network (other part of topic #4) [33,34]. Let's observe that most of these articles (9 among 11) are dealing with subjects that are quite similar to the traditional application of TRIZ based methods, i.e. design of products and design of manufacturing process. ...
... This is done by an interpretation of the Cleaner Production strategies in regard of the TRIZ laws of evolution. In 2012, a method to solve the contradictions between Lean and Green Design strategies is proposed in [29]. More recently in 2013, a method based on the Ideal Final Result, a TRIZ model to maximize the use of the resources naturally present in the environment of the problem, was proposed in order to solve green production problems [31]. ...
Green supply chain management has emerged as green
innovation that integrates environmental aspects in the supply chain. It is generally named “green logistics”. As this field deals with innovation, this paper aims to focus on how specific inventive methods face with this innovation problematic in green logistics. The objective of this paper is then to answer the following question: How canand may TRIZ (Theory of Inventive Problem Solving) contribute to solve the problems of green logistics? To do so, in this paper we mainly focus on papers referring to past experiences of using TRIZ for addressing problems related to green logistics.They are first analysed within the framework of TRIZ potentials and green logistics areas,then unexplored areas are highlighted.
... According to the authors, shows combining TRIZ with Lean approaches allows companies to manage their products more effectively throughout their lifecycles, resulting in improved product end-of-life and recycling management. (Bashkite and Karaulova 2012) proposes a methodology to facilitate the understanding of the TRIZ methodology for combination of Green and Lean practices. (Navas and Machado 2013) integrates TRIZ analytical tools with Lean techniques, to assure the sustainability of production system management. ...
The aim of this article is to improve the performance of production systems by integrating Lean tools and functionalities from the design phase, thereby reducing the need to apply them during the use phase of future manufacturing systems. This implies a change of mindset; instead of reacting to problems as they arise and then implementing Lean to remedy them, companies should proactively integrate it from the design phase. However, trying to integrate several Lean tools and functionalities into the design of a production system to satisfy multiple performance criteria can generate contradictions. For this reason, we propose a new methodology: Lean Parameter Integration Matrix (LPIM), which can be used to resolve the different types of problems. LPIM contains a set of generalized Lean parameters extracted from the Lean tools most used in companies. It allows the simultaneous identification of technical and physical contradictions that may arise from the integration of multiple Lean tools and their functionalities, and provides guidance for their resolution, using the principles of TRIZ methodology for resolving technical and physical contradictions.
... The philosophy, Lean Manufacturing is used by many organizations to improve the business process by eliminating waste. Many research found that the lean concept is contributing to the development of the organization by improving the productivity in the business activities (Ranaweera, 2010; Wickramasinghe and Wickramasinghe, 2017), generates Social and environmental benefits [30][31][32][33]. But according to the (Antony,2011), a Lean manufacturing system is appropriate to accelerate the speed and the reduction of waste and the methodology Six Sigma is appropriate for process evaluation, defect reduction, and variation [34]. ...
Six Sigma is a project-driven approach to improve business performance error-free. This study is an applied and mixed-method study that focuses on applying Six Sigma Methodology to improve the sub-assembly line of a bicycle manufacturing system. The main objective of the study is "To improve the assembly line production system by reducing the cycle time, applying Six Sigma Methodology in the bicycle production system in ABC Company" To achieve the main objective of the study, two sub-objectives are addressed. "To identify the relationship between the contribution of the operator's delay time to the total production time to reduce the cycle time of the sub-assembly line." and "To identify whether there is a significant difference between the cycle time of the sub-assembly the line before and after the Six Sigma application." Primary data are collected for the 30 sample units, related to the time performance of the sub-assembly line operators and interviews are conducted with 05 employees to get an idea about the current process. The direct observation method is used to collect data from the sample. DMAIC methodology (D-Define, M-Measure, A-Analyze, I-Improvement, C-Control) which is discussed in Six Sigma is applied and under it Correlation analysis, Pareto analysis, range chart and mean chart, Cause and effect diagram are used to analyse the data. Analysis data revealed that the current process can be found with random and assignable variations, and it is not under control. The viewpoint of Men, Methods, Materials, Machine causes are affected by the higher cycle time of the sub-assembly line and make a deviation to unbalance the assembly line. All the operators positively contributed to generating delay time to the total production time of the sub-assembly line. By applying the Six Sigma methodology, the sub-assembly line is redesigned and balanced with reducing one operator and providing more facilities to the sublime. By applying the Six Sigma methodology the Sigma level increased from 0.8-8.5 level to 2.2 to 2.3 levels. One tail sample t test indicates that the cycle time is reduced due to the Six Sigma methodology. It can be concluded that Six Sigma methodology can be successfully applied to improve the sub-assembly line production system by reducing the cycle time of the bicycle manufacturing process of ABC Company.
... The philosophy, Lean Manufacturing is used by many organizations to improve the business process by eliminating waste. Many research found that the lean concept is contributing to the development of the organization by improving the productivity in the business activities (Ranaweera, 2010; Wickramasinghe and Wickramasinghe, 2017), generates Social and environmental benefits [30][31][32][33]. But according to the (Antony,2011), a Lean manufacturing system is appropriate to accelerate the speed and the reduction of waste and the methodology Six Sigma is appropriate for process evaluation, defect reduction, and variation [34]. ...
Six Sigma is a project-driven approach to improve business performance error-free. This study is an applied and mixed-method study that focuses on applying Six Sigma Methodology to improve the sub-assembly line of a bicycle manufacturing system. The main objective of the study is "To improve the assembly line production system by reducing the cycle time, applying Six Sigma Methodology in the bicycle production system in ABC Company" To achieve the main objective of the study, two sub-objectives are addressed. "To identify the relationship between the contribution of the operator's delay time to the total production time to reduce the cycle time of the sub-assembly line." and "To identify whether there is a significant difference between the cycle time of the sub-assembly the line before and after the Six Sigma application." Primary data are collected for the 30 sample units, related to the time performance of the sub-assembly line operators and interviews are conducted with 05 employees to get an idea about the current process. The direct observation method is used to collect data from the sample. DMAIC methodology (D-Define, M-Measure, A-Analyze, I-Improvement, C-Control) which is discussed in Six Sigma is applied and under it Correlation analysis, Pareto analysis, range chart and mean chart, Cause and effect diagram are used to analyse the data. Analysis data revealed that the current process can be found with random and assignable variations, and it is not under control. The viewpoint of Men, Methods, Materials, Machine causes are affected by the higher cycle time of the sub-assembly line and make a deviation to unbalance the assembly line. All the operators positively contributed to generating delay time to the total production time of the sub-assembly line. By applying the Six Sigma methodology, the sub-assembly line is redesigned and balanced with reducing one operator and providing more facilities to the sublime. By applying the Six Sigma methodology the Sigma level increased from 0.8-8.5 level to 2.2 to 2.3 levels. One tail sample t test indicates that the cycle time is reduced due to the Six Sigma methodology. It can be concluded that Six Sigma methodology can be successfully applied to improve the sub-assembly line production system by reducing the cycle time of the bicycle manufacturing process of ABC Company.
... It specifies "being aware of our interconnectedness with the world and reflecting on the unintended damage we cause to nature in the daily course of our lives" (The Environmental Action Alliance, 2004, p. 1). Recognizing conditions under which individuals are involved in green thinking represents an influential research agenda (Bashkite & Karaulova, 2012). Recently, Ali et al. (2020) examined the direct effect of green thinking on the purchase intention of green electronics products. ...
This study aims to provide an understanding of the role of green transformational leadership (GTL) and green innovation practices in organizations through cognitive processes: green thinking and creative process engagement (CPE). Using a survey questionnaire, we collected data from 342 respondents from high‐tech industries located in China. The data were examined through structural equation modeling (variance‐based) to analyze the hypotheses. The findings of the study show that GTL has a substantial effect on green thinking, CPE, and green innovation. The findings further reveal that green thinking and CPE mediate the relationship between GTL and green innovation. Green thinking and creative processes have become instrumental tools in fostering green innovation. Thus, this investigation provides novel insights into how to promote GTL and cognitive processes in organizations to solicit green innovation.
... Additionally, are available web sites that provide effects database for users [51], [52]. As mentioned by Bashkite and Karaulova [53], the method of TRIZ is to break the psychologic barrier, to abstract from the initial problem. ...
Lean Thinking philosophy pursuit continuous improvement and continuous innovation towards economic and eco-sustainable growth by new solutions. Such solutions involve eco-efficient products (goods and/or services) and cleaner production to produce them. Nevertheless, sometimes, there are technical contradictions that inhibited companies to achieve good solutions. TRIZ is a methodology capable to solve such contradictions and Lean could use it. Lean and TRIZ are on the road to achieve sustainable development goals, directly, the Goal 12, responsible consumption and production. This paper presents some case studies where this alliance is recognized and credited. These case studies were collected and synthetized by: type of work developed, company/sector, main TRIZ and Lean principles and tools used, problem(s) to solve and products/solutions designed. Building on the results, the authors systematized that Lean and TRIZ impact the design of creative solutions. Many of such solutions were developed in students’ master dissertations that reveals the importance of teaching Lean allied with TRIZ.
... Many firms continue to move toward just-in-time manufacturing (aka Toyota production system, short-cycle manufacturing, lean, etc.) for obvious time and cost saving advantages (Dennis 2016); this is being spurred in part by the increasing ease of data collection from the "Internet of Things" (Zhang, Zhang et al. 2015). These continuous improvement techniques try to do more with less; they can also be key circular economy approaches with wide ranging implications for criticality mitigation (Bashkite and Karaulova 2012). Lean manufacturing is a management approach focusing on increasing efficiency and eliminating waste via continuous monitoring and reporting of specific key performance indicators referred to as KPIs. ...
Raw materials deemed critical are defined as having potential issues in their supply, limited substitutes, and applications of importance, namely in clean energy, defense, healthcare, and electronics. Disruptions in supply of critical materials can have serious negative repercussions for firms, consumers, and economies. One potential set of mitigation strategies for firms dealing with criticality issues is the implementation of circular economy principles in their supply chain, operations, and end-of-life management. This work conducts a literature review combined with case study analysis to examine how certain firms assess and monitor their vulnerability to critical material supply chain issues and provides specific business examples for integrating circularity strategies. Results indicate the potential for risk reduction that could be gained from implementation of these strategies; specifically recycling, for example, can provide an in-house source (for prompt or fabrication scrap) or at least domestic source (for post-consumer scrap) for critical materials; up to 24% for the case of indium usage in China. Just in time manufacturing techniques have the potential to both exacerbate supply issues (by encouraging low inventory or needed resources for manufacturing) and improve supply issues by introducing resiliency in the supply chain indicating that approach of firms in undertaking these strategies is important. Many cases reviewed show other quantifiable secondary benefits beyond risk reduction, such as economic savings, reduction in energy consumption, and improved corporate social responsibility via enhanced supply chain oversight.
... -Direct Application of TRIZ methods and tools without considering the three axioms of the TRIZ -Adaptation of TRIZ methods and tools to GSC problems -Systemic application of TRIZ methods and tools that account for the three axioms of the TRIZ Indeed, the direct application of some TRIZ tools and methods to green design is obvious and was established in several articles (Chen & Chen 2007;Rau & Fang 2009;Bashkite & Karaulova 2012). However, these direct applications, which primarily focused on the use of the matrix for technical contradiction, have the same limits as those that can be formulated regarding the matrix, that is used in the design of technical systems when no green constraints are considered. ...
The purpose of the paper is to review the practice of the theory of inventive problem solving (TRIZ) in Green Supply Chain (GSC) problems and to identify new research challenges focusing on the question: “To what extent is it necessary to evolve TRIZ tools, methods and theoretical grounding for addressing GSC inventive problems?” First, a review of the past contributions of TRIZ based methods to GSC problem resolution is presented. As the result of the papers review did not provide a comprehensive understanding of the limitations and areas of potential application of TRIZ in GSC, three experiments were conducted to complete the literature review, in order to provide a more comprehensive answer to the posed question and identify research challenges. The experiments addressing GSC problems were also conducted to explore to what extent the more mature meta-methods of classical TRIZ, namely ARIZ 85 A, C and the related sub-methods, can be used as in GSM problems. The examples were chosen to explore types of GSC problems that were not yet addressed with TRIZ. The experiment results highlight limitations on the use of the TRIZ in GSC inventive problems, which were not mentioned in the GSC literature. Moreover it highlights the limitation of using the more mature meta-methods of TRIZ (ARIZ 85A and ARIZ 85C) when the conflict to overcome contains more than two evaluation parameters and one action parameter. Finally, research challenges to overcome the limitations and to improve the use of TRIZ in GSC inventive problems are stated. Among them, methods for quickly establishing the existence of classical TRIZ contradictions or for informing the problem solver when no TRIZ contradictions are present in a given inventive problem in GSC should be proposed. Such methods would permit determining whether ARIZ 85C could be used and avoid a long and fruitless search for a system of contradictions. Find alternatives to the algorithms proposed in the past to be able to establish the generalized contradictions of inventive problems. Make evolve meta-methods ARIZ 85C or substitute it with methods which can address the inventive problems that cannot be treated by ARIZ 85C.
... Lean, a management philosophy derived from TPS (identified as lean in the 1990s) is centered on making evident what adds value to the end product by reducing everything else (Womack and Daniel, 1990;Holweg, 2007), whereas, TPS is known for its focus on the reduction of original Toyota seven wastes for improving the overall customer value, but still there are varying perceptions on how this can be best achieved. Henry Ford, one of the first people to who developed the philosophy behind lean manufacturing through 'continuous flow' concept on the assembly line of an automobile, where he kept the production standards extremely tight, and this resulted in reduced waste; Gustashaw and Hall (2008) conferred lean & environmental sustainability and broaden the operational considerations from internal efficiency to their effects on external processes; Laird (2012) stated that eliminating energy waste is equally important to industries as a result of rising energy costs; Post and Slaughter (2000) supposed that lean's reduction of inventories & workers makes it vulnerable and hence the need to replace capitalism with democratic socialism; argued that ISO 14001 standards and lean principles can achieve the continual improvement ideas; Chahal (2012) focussed on producing high quality products along with flexible manufacturing that help businesses remain competitive & sustainable over long term; Bashkite and Karaulova (2012) proposed methodology to facilitate the understanding of TRIZ (Theory of inventive problems-solving) that present the integration model by developing the matrix for contradiction solving of green-lean. Whitman et al. (2008) presented the existing simulation based virtual factory and the application of modern production systems along with the integration of sustainability; Florida (1996) examined the link between advanced production & environmentally conscious manufacturing via survey, phone interviews and field research. ...
Despite of its type, location or principal market base, today the manufacturing enterprises are bound to adopt sustainable practices like lean principles, integration of processes and inter-organizational collaborations to meet their corporate goals. The majority of studies usually discuss either a system or a subcomponent of the production systems and manufacturing strategies in literature w.r.t. lean production; but the rational (what, why, how) behind each production activity seems to be missing. This paper addresses a comprehensive assessment of the literature on lean production in relation to the green concept, for its significance, feasibility and need for organizations to sustain in the global market. Findings of the review reveal that lean principles along with green model can improve the process flow & employee morale and lower the environmental regulatory non-compliance risk. Further, the environmental and human health risks are often not explicitly considered in lean initiatives that can affect customers & stakeholders throughout the product life cycle, and the manufacturing enterprises working with lean strategies have the possibility of costs sub-optimization and waste reduction from a lifecycle viewpoint.
... Altshuller analysed a big number of Russian patents for generic principles how the patented solutions were arrived at. He identified the following laws of evolution of technical systems [14,15]: ...
Nowadays it is absolutely clear all the enterprises are focused on cost reduction and resources efficiency to stabilize their position in competitive and economically variable market. Environmental policies and local authorities push manufacturing companies to produce in a clean and green way by using well-known philosophies like lean and green manufacturing, kaizen (continuous improvement) and etc. Everything mentioned above can help to overview and improve manufacturers' internal and external processes. Innovation is one effective approach to develop product life cycle and take control over internal issues concerning profitability of used industrial equipment. This paper is mostly focused on finding best standard or innovative end-of-life (EoL) solution for used industrial equipment life cycle extension by implementing Theory of Inventive Problem-Solving tools (TRIZ). (C) 2014 The Authors. Published by Elsevier Ltd.
The classification of land use / land cover (LU/LC) for certain area plays a major role in planning, management, and monitoring programs as well as it helps to study the changes which are happening in the environment and ecosystem. This study aims to evaluate LU/LC changes in Hambantota Divisional Secretariat Division from 2008 to 2019. Hence LU/LC cover changes spatially with time; this study is conducted by using supervised classification, particularly maximum likelihood classification and accuracy assessment using Remote Sensing and GIS techniques. The results revealed that the increment of water bodies (2.39%), agriculture (0.44%) and built-up areas (27.66%), and decrement of barren lands (11.61%) and forest cover (18.88%) with the time due to the vast development over the years. The overall accuracy for both 2008 and 2019 ranged from 86.7 percent to 83.3 percent and the Kappa coefficient ranged from 0.888 to 0.912.
Current research is focused on the decision-making framework development with Lean and Green Manufacturing tools and End-of-Life scenario consideration. A specific mechanism was developed for used industrial equipment life cycle extension in order to save money, nature, and society. The proposed framework makes business more profitable by including an innovative approach of using complex TRIZ to make it more universal and easy to use for the largest variation of used industrial products. Development of an approach for used industrial product assessment improves company inventory controllability and utilization that in turn minimizes environmental impact and resource consumption during the entire product cycle.
During the last 50 years manufacturing industry has been developing various methods to decrease lead times and reduce manufacturing costs. Most of those improvement methods are nowadays referred as lean manufacturing. In the construction industry lean techniques have also been adopted. However, lack of integrated material control solutions through the lifecycle of projects is a major hurdle to practice lean techniques. Due to natural complexity of construction projects, it is very difficult to establish transparent material information flow in the real time. In this paper, authors present an integrated framework for computer-aided design (CAD) and enterprise resource planning (ERP) systems. This integration enables to improve the strategic advantage of construction companies in the terms of production costs and customers' satisfaction.
Cost-effective manufacturing and technology-based manufacturing are basic keywords in contemporary manufacturing. Efficiency and productivity require extremely good job management, correlation of resources and competencies to production requirements, as well as continuous monitoring of possible wastes and additional expenditures, i.e. real efficiency of the continuous improvement process. In the current article the methodology of technological resources and competence management evaluation in terms of manufacturing system ontology are analysed in pre-order and post-order fulfilment stages. The expedience of resources operation and order outsourcing, but also corresponding risk management principles are analysed. The elaborated methodology enables enterprises to implement a more rational utilization of manufacturing resources by estimating the influence of existing competencies and technological possibilities into productivity and efficiency.
This book examines the evolution of environmental policy in 6 OECD countries. It contrasts the widely-varying political and regulatory styles and their consequences for innovation. The author includes two industry-specific studies which provide a transnational perspective on the co-evolution of technology and environmental policy. The book addresses issues such as: how can policy makers pursue environmental goals while simultaneously keeping the burdens on industry to a minimum? Why does innovation play a key role in this balancing act, and what are the implications for the development of sustainable industrial societies? The author concludes that innovation can be successfully harnessed by setting credible, long-term environmental goals and ensuring that regulatory instruments are grounded in flexibility, dialogue and trust. -from Publisher
This paper intends to present and discuss a review of actual supply chains management paradigms. A conceptual model to provide the necessary understanding of paradigms divergences and commitments is addressed, contributing to a more sustainable and competitive supply chain. A literature review related to lean, agile, resilient and green supply chain management paradigms is presented, identifying the attributes of each paradigm and their impact/consequence in the supply chain. A conceptual model exploring supply chain management characteristics and paradigm inter-relationship is discussed. The main objective is to identify the supply chain characteristics that must be managed to obtain: the necessary organizational agility; to speed-up the bridging between states that require more or less degree of resilience; to preserve the dynamic aspects of the lean paradigm and; to assure its harmonization with the ecologic and environmental aspects that production processes may attend.
