Implementing lean practices in manufacturing SMEs: testing ‘critical success factors’ using Necessary Condition Analysis

Lean practices are known to increase operational performance. Previous research has identified critical success factors for implementing lean practices. This research aims to examine the extent to which success factors are critical for various degrees of lean practice implementation. Using multiple-respondent self-assessments from 33 Dutch manufacturing small and medium-sized enterprises (SMEs), we conducted a Necessary Condition Analysis. Our findings indicated that the criticality of success factors is progression dependent. In the initial stages of the lean journey, SMEs could improve their lean practices in a bottom-up manner through local factors such as a learning focus, improvement training and support congruence. When lean practices are more advanced, some company-wide factors must be present: top management support, a shared improvement vision and a supplier link. Our findings question the universality of success factors such as strategic involvement and indicate the need for a more dynamic model of lean implementation.     

Geochemistry of trace metals in a fresh water sediment: field results and diagenetic modeling

Concentrations of Fe, Mn, Cd, Co, Ni, Pb, and Zn were determined in pore water and sediment of a coastal fresh water lake (Haringvliet Lake, The Netherlands). Elevated sediment trace metal concentrations reflect anthropogenic inputs from the Rhine and Meuse Rivers. Pore water and sediment analyses, together with thermodynamic calculations, indicate a shift in trace metal speciation from oxide-bound to sulfide-bound over the upper 20 cm of the sediment. Concentrations of reducible Fe and Mn decline with increasing depth, but do not reach zero values at 20 cm depth. The reducible phases are relatively more important for the binding of Co, Ni, and Zn than for Pb and Cd. Pore waters exhibit supersaturation with respect to Zn, Pb, Co, and Cd monosulfides, while significant fractions of Ni and Co are bound to pyrite. A multi-component, diagenetic model developed for organic matter degradation was expanded to include Zn and Ni dynamics. Pore water transport of trace metals is primarily diffusive, with a lesser contribution of bioirrigation. Reactions affecting trace metal mobility near the sediment-water interface, especially sulfide oxidation and sorption to newly formed oxides, strongly influence the modeled estimates of the diffusive effluxes to the overlying water. Model results imply less efficient sediment retention of Ni than Zn. Sensitivity analyses show that increased bioturbation and sulfate availability, which are expected upon restoration of estuarine conditions in the lake, should increase the sulfide bound fractions of Zn and Ni in the sediments.     

The Multi-Mode Resource-Constrained Multi-Project Scheduling Problem

Scheduling projects is a difficult and time consuming process, and has far-reaching implications for any organization’s operations. By generalizing various aspects of project scheduling, decision makers are enabled to capture reality and act accordingly. In the context of the MISTA 2013 conference, the first MISTA challenge, organized by the authors, introduced such a general problem model: the Multi-Mode Resource-Constrained Multi-Project Scheduling Problem (MRCMPSP). The present paper reports on the competition and provides a discussion on its results. Furthermore, it provides an analysis of the submitted algorithms, and a study of their common elements. By making all benchmark datasets and results publicly available, further research on the MRCMPSP is stimulated.     

Sequence-dependent clustering of parts and machines: A Fuzzy ART neural network approach

This study addresses the problem of identifying families of parts having a similar sequence of operations. This is a prerequisite for the implementation of cellular manufacturing, group technology, just-in-time manufacturing systems, and for streamlining material flows in general. A pattern recognition approach based on artificial neural networks is proposed, and it is shown that the Fuzzy ART neural network can be effectively utilized for this application. First, a representation scheme for operation sequences is developed, followed by an illustrative example. A more comprehensive experimental verification, based on the mixture-model approach is then performed to evaluate its performance. The experimental factors include size of the part-machine matrix, proportion of voids, proportion of exceptional elements, and vigilance threshold. It is shown that this neural network is effective in identifying good clustering solutions, consistently and with relatively fast execution times.     

The impact of team and work characteristics on team functioning

In this article, the authors seek to strengthen the theoretical foundation of team and cell formation through the inclusion of human factors. They distinguish three types of team characteristics: global, shared, and compositional attributes. In this last category, they also deal with diversity in teams by addressing three types of variables: demographic characteristics, skills and knowledge, and personality traits. In addition, the authors address the relevance of the structure of diversity in cells. For each of the above‐mentioned groups of team characteristics, their potential impact on team functioning is worked out and discussed with simultaneous consideration of the characteristics of the team task. Three industrial examples are included to illustrate the importance of including worker, team, and work characteristics when designing manufacturing cells. © 2006 Wiley Periodicals, Inc. Hum Factors Man 16: 1–15, 2006.     

Rapid detection of stressed Salmonella spp. in dairy and egg products using immunomagnetic separation and PCR

The rapid detection of an average of 5.9 stressed Salmonella cells in 25 g of food product using immunomagnetic separation (IMS) and PCR is described. For pasteurised egg yolk, egg yolk powder, ice-cream, whole egg, egg white and cheeses made from pasteurised milk PCR was applied after 16 h of preenrichment in buffered peptone water (BPW) using IMS and alkaline lysis as sample preparation method. For whole egg and egg white the BPW was supplemented with iron. For milk powder, and raw milk cheeses, the 16-h preenrichment in BPW was followed by IMS and a 4-h enrichment in Rappaport-Vassiliadis broth. In the latter case, PCR was applied on the enrichment medium after centrifugation and alkaline lysis. For PCR the primers ST11 and ST15 (Aabo et al., 1993) producing a fragment of 429 bp were used. An internal PCR control, designed to be co-amplified with the target DNA using the same primers but producing a smaller fragment of 240 bp, was used.     

Development and evaluation of cross-training policies for manufacturing teams

This study addresses the problem of developing and evaluating cross-training policies for manufacturing teams from a Human Resource Management (HRM) and Operations Management (OM) viewpoint. A cross-training policy can be regarded as a set of rules to determine the distribution of workers' skills. The specific way in which workers and machines are connected determines the agility of the workforce. In this article, we develop an integer goal programming model to support a consequent application of alternative cross-training policies. A simulation study is performed to assess the performance of the resulting cross-training configurations within three routing structures: a parallel structure, a serial structure, and a job shop structure. Results indicate that within all routing structures, the focus of cross-training policies depends on whether a HRM or an OM viewpoint is considered. Within the parallel and the serial structures, however, HRM and OM goals are compatible and can be integrated within a single cross-training policy. Within the job shop structure, the integration of both OM and HRM goals within one cross-training policy is more difficult.     

Family-based dispatching: anticipating future jobs

Group Technology exploits similarities in product and process design to meet the diversity of customer demand in an economic way. In this paper we consider one of the implementations of this concept?–?family-based dispatching. Intrinsic to family-based dispatching is the grouping of similar types of products for joint processing. In this way the number of set-ups may be reduced. Consequently, lead-time performance of the shop can be improved. We extend existing rules for family-based dispatching by including data on upcoming job arrivals. Typically, this type of data resides in the minds of the operators, or is stored in a shop-floor control system. Its availability allows for (1) better estimates of the composition of a process batch for a family, (2) the consideration of families for which no products are available at the decision moment, and (3) the possibility to start set-ups in anticipation of future job arrivals. The potential of including forecast data in decision-making is demonstrated by an extensive simulation study of a single-machine shop. Results indicate the possibility of significant improvements of flow time performance.     

High herd-level prevalence of Mycobacterium avium subspecies paratuberculosis in Western Canadian dairy farms,based on environmental sampling

Mycobacterium avium subspecies paratuberculosis (MAP) causes chronic progressive enteritis in ruminants. The pathogen is present in most countries with modern dairy production, causing substantial economic losses for the industry. The objectives of this study were to estimate dairy herd prevalence of MAP in the Western Canadian provinces of Alberta and Saskatchewan, and to determine whether herd size and housing system (tie-stall versus freestall or loose housing) affected the risk of a herd testing positive for MAP. Six environmental samples were collected on 360 Alberta farms (60% of registered producers) and on 166 Saskatchewan dairy farms (99%). In total, 47% of the sampled farms in Alberta and 53% of the sampled farms in Saskatchewan had at least one environmental sample that was MAP culture positive and were, therefore, defined as infected. Sensitivity of environmental sampling was estimated using 3 subsequent annual tests performed on 82 farms. Because laboratory protocols were continuously improved throughout the project, the sensitivity increased over time. Therefore, a mean of the sensitivity estimates weighted on sampling year was constructed; this resulted in sensitivities of 68 and 69% for Alberta and Saskatchewan, respectively. Implementing those estimates in an approximate Bayesian computation model resulted in a true herd prevalence of 68% (95% probability interval: 60–80%) for Alberta and 76% (95% probability interval: 70–85%) for Saskatchewan. Herds with >200 cows had 3.54 times higher odds of being environmental sample positive and had more positive samples than herds with <50 cows (neither province nor housing system affected those results). In conclusion, the majority of Alberta and Saskatchewan dairy farms were infected with MAP and larger herds were more often MAP positive than smaller herds.     

Impact of lean interventions on time buffer reduction in a hospital setting

This paper focuses on performance changes stemming from a series of lean interventions in a medical laboratory. This research is one of the first to link a series of lean interventions and performance over time. In a mixed-method case study, six years of patient-related throughput data, retrieved from a laboratory computer database, are analysed. Three distinct periods with significant differences in throughput time performance can be distinguished. Semi-structured interviews were held to investigate the lean interventions preceding the performance changes. Given the long-term nature of the study, the event history calendar method was applied to enhance the respondents’ recall and reliability. A single lean intervention, among the hundreds that took place, was supposed to cause the main reduction in throughput times. It concentrated on improving process flow through the removal of batching, a source of artificial variability. A later major intervention, the introduction of flow-focused machinery, had mixed effects and initial performance gains were not sustained. The results show that ongoing series of interventions do not always lead to ongoing performance improvements in terms of throughput times but support theories emphasising the importance of variability reduction.