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The stages of the Gemba Kaizen event and their relationship with the phases of process management and its performance.
Source publication
This paper presents a real application of a lean–green improvement initiative conducted at a large Portuguese hypermarket store. It explores how lean tools and techniques may be used to not only improve the operational performance, but also sustainability. A case study was carried out in one store of a multinational retail enterprise, with the aim...
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Lean thinking is transforming the traditional way of a retail business operates to new and more effective practices. In particular, the food retail business is facing previously unseen challenges which require daily operational excellence to meet them with success. Low productivity, high variability in task completion, lack of work planning should...
The article presents the results of conducted empirical research in which an attempt was made to identify the expectations of manufacturing companies towards suppliers in terms of process (logistics customer service, supervision over property customer, production monitoring, supplier supervision) improvement. The research was conducted using the Co...
Citations
... Optimization model(Based on Schoeman et al., 2020;Zhu et al., 2020;Morales Méndez & Rodriguez, 2017;Robertsone et al., 2021;Indah et al., 2020;Marques et al., 2022;Tanash et al., 2022;Ebrahimi et al., 2023;Toki et al., 2023; Ortiz Vigo et al., 2023;Thanki & Thakkar, 2018). ...
The textile industry represents one of the greatest threats to the environment. It is the second most polluting industry, generating hazards with its solid waste, gas emissions, water pollution, among others. The objective of this research was to assess the effects of the implementation of the Lean Green methodology within the textile industry to optimize the sustainable performance of the companies and to address the problems of the sector mentioned above. The case study selected was the dyeing area of a Peruvian textile company where the Lean Green methodology was implemented in a sequential design of six phases to then evaluate its effects on sustainable performance. The findings show that the implementation of the proposed model improves water consumption by 18% and electricity consumption by 43%, which has a positive economic impact. Not only in the environmental area, there is also a 120% increase in productivity. The value of this proposal lies in the fact that it can be replicated in other companies in the sector, both locally and regionally. It was also proposed to include the operational criterion in the measurement of sustainable performance for a better dimensioning of the improvement.
... The two major baked goods, biscuits and bread, account for 82% of all baked goods production. Cookies are freshly baked foods, usually flourbased foods [5]- [7]. ...
Among all food sectors, the Indian biscuit industry appears to be the biggest and only makes a profit of about Rs. 3000 crores. In this biscuit industry, the retailer applying the retail marketing strategy that means the process in which retailers promote awareness and interest of their goods and services in an effort to generate sales from their consumers. Retailers use various advertising and communication tools to grow awareness and considerations with future customers. In this research, the researchers try to find the retailer preference towards biscuits industry in Chennai. The major goal is to determine the retailers' satisfaction by assessing the impact of the promotional mix and retailers' perceptions regarding cookies and biscuits. The information was gathered utilising a structured questionnaire from 125 retailers and a convenience sample strategy. This study's research design is primarily descriptive in nature. The SPSS software is applied in this study's analysis of the data. Branding is a critical factor when buying cookies and biscuits. Most of the retailers have maintained positive relationships with their dealers and are satisfied with the cookies' quality and brand value. The retailers suggest that the company is to increase the samples and the free gifts offered by the festival period of time and at the same time they wish to obtain more discounts and offers expected by them. The cookie industry raises the business's brand recognition among consumers as well as retailers.
... This was due to inefficient inventory control and supply processes and the need for more standardization. For this reason, LIM tools have been used to improve inventory management, such as MRP, which increased the company's total profit by 4% by reducing the percentage of defective products from 11.43% to 6.67% [9], addition, in a study conducted in a company producing noodles that have overstock due to the delay in receiving raw materials, it was decided to implement an efficient inventory control system so that through an MRP could determine the necessary quantities to be requested for raw materials and when to do so to solve the problem of overstock [10]. ...
This study focuses on developing a solution to one of the main problems in the food sector, product deterioration, often due to poor inventory management, low turnover, and lack of shelf-life control, among other causes. Therefore, this study is based on the design of a lean inventory management model proposed to reduce the number of deteriorated products in an egg product company in Peru, based on the analysis of the problem within the company and the study of previous research. As a result, the proposed method uses the tools of Machine Learning, Material Requirement Planning (MRP), 5S, and First Extended First Out (FEFO), reducing the main problem by 65.57% and the demand forecast error by 47.21%, thus reducing one of the leading root causes of the main problem. Thanks to this improvement, this research can contribute knowledge so that other companies with similar issues can implement the model and improve their results.
... Worldwide, food waste (FWP) has been recognized as a sustainability problem due to its negative impact on society at an economic, social and environmental level (Marques, Carvalho & Santos, 2022; Economic Commission for Latin America and the Caribbean -ECLAC, 2020) as in the world a average of 1,300 million tons of food is wasted (Kolawole, Mishra & Hussain, 2021) with 66% being the product of deterioration or decomposition (Wu, Mohammed & Harris, 2021). Peruvian food industry has not been exempted from this situation, since although favorable results in its growth are shown (from 9% in 2020 to 8.5% compared to 2019) (SNI, 2022: page 16) a solution to food waste has not been found yet (Vázquez-Rowe, Ziegler-Rodriguez, Margallo, Kahhat & Aldaco, 2021) generating the need of a proper management on its processes through continuous improvement (CI) projects to reduce waste, increase productivity and reduce environmental impact. ...
Purpose: Food waste is a latent problem for society, one of the main causes being poor management of the operating processes within the food industry, which is the main reason the present research aimed to reduce raw material waste in a nectar factory.Design/methodology/approach: The methodology led to carrying out an experimental investigation where a Green Lean Six Sigma Model was applied, whose foundation was the use of tools such as Environmental Value Stream Mapping (E - VSM), DMAIC (Define - Measure - Analyze - Improve - Control), Poka Yoke and DOE (Design of Experiments), the data obtained were exposed to an inferential statistical analysis using tests such as Anderson - Darling and T-Student.Findings: As a final result, a waste reduction of 2.23% was obtained, which is equivalent to approximately 120 kg of useful raw material, in addition the environmental impact was reduced by 2.2%, waste costs were also reduced by approximately 5.5% and produced an increase in global productivity by 2.4%.Research limitations/implications: It is shown that the application of methodologies such as Green, Lean and Six Sigma in the food industry present benefits during and after the application of the model; such as preventive control of waste, standardization in processes; benefits that, in coordination with an organizational culture of continuous improvement, can significantly improve the current state of companies.Practical implications: The positive obtained results support the methodology proposed by the authors to reduce the waste of agricultural raw material. It is expected to be a benchmark for other similar organizations that seek to generate greater productivity in line with the search for environmentally sustainable operations.Originality/value: This is one of the first studies that aims to reduce the waste of raw materials in food processing companies, considering aspects of mitigating environmental impact.
... The authors of [68] describe the improvement of operational and sustainability performance using lean management specifically Gemba Kaizen. The team found that the cutting process was incorrectly done and led to waste. ...
The energy crisis, an increasing concern of the industrial sector, is characterized by increased energy costs and low energy availability. As part of an effort to increase energy efficiency, the present study assessed the impact of applying lean tools on the energy consumption of a manufacturing organization. Using the Kaizen approach, the organization’s processes were analyzed to identify the main vulnerabilities and make the required changes to increase consumption performance. Several technical improvements were performed to reach increased energy efficiency. Results showed an energy efficiency increase; consumption was reduced by up to 7.5% in the production line, 3.5% in the extruder stage, and up to 20% for the injection stage of the manufacturing process. The results suggest that the organization’s energy reduction targets have been achieved. Standardization of procedures was useful in the development of Kaizen projects which could be applied with certain limitations. The implications of these results for understanding energy consumption reduction are discussed.
... The definition is expanded further, as DMAIC is applied to enhance value and eradicate all nonvalue activities. Marques, Carvalho, and José [2] show another successful application of process improvement tools to improve retail operations, while considering sustainability. This principle is also important for FSI, as most materials are perishable organic components, such as leaves and flowers. ...
... A study in Egypt found that the lifecycle assessment approach could help the 343 tomato supply chain companies avoid food loss [22]. An extensive review of studies on waste management in both developing countries such as India, Malaysia, and Saudi Arabia [23][24][25][26] and developed countries, e.g., Switzerland [27], was conducted involving, e.g., the lifecycle assessment approach using an innovative supply chain [28] and dumping of rock-hard waste [29]. The research provided a framework for sustainable management [30], recommending that those concerned follow the municipal solid waste standards [31] and employ a validated technology acceptance model [32]. ...
Overflowing garbage bins and unnecessary truck visits to collect waste have always been core issues of sustainability and maintaining a green environment. In the recent past, a transition has been observed in waste management towards a better environment and the achievement of sustainability goals. Companies are not only focused on producing less but also transforming waste into energy and reusable products. This transition process needs to evolve through sustainable solutions and innovative marketing initiatives that increase awareness and education among end users. This study used a systematic literature review protocol to identify and review the available research on sustainable waste-management solutions, innovative marketing initiatives, and a proposed conceptual model. It analyzed the latest literature from 1976 to 2022 to assess waste-management trends using the Web of Sciences and Scopus databases. To evaluate the practical perspective, this study analyzed ten waste-management companies offering services in the USA, the UK, Korea, Finland, Ireland, Turkey, Brazil, Slovakia, Portugal, Denmark, and Canada to assess their technological and marketing development for the creation of a better future. It was found that Ecube, Enevo, smart bins, Compology, Bigbelly, Sensoneo, Citibrain, ACO recycling, Evrek, Rico, and BrighterBins focus more on technology and less on user awareness and marketing. There is minimal focus on education and empowerment of end users. Our study’s findings guide academics, practitioners, and policymakers to apply ambidextrousness in energy innovation, particularly in the waste-management sector. By implementing sustainable and innovative solutions, companies can not only reduce waste products, but they can also recover, recycle, and better dispose of the waste. However, to do so, companies also need to educate end users.
... We must use each tool to understand when, where, why, and how to produce a successful DMAIC process. Most lean tools belong to the improvement and control phases of DMAIC, but once an opportunity has been identified, there is no reason not to use them immediately [36]. Thus, more studies based on the integration of LSS and VSM 4.0 are required. ...
Many industries have successfully implemented the define-measure-analyze-improve-control (DMAIC) method of Lean Six Sigma to improve their production activities. Value stream mapping (VSM) for Industry 4.0 allows us to understand the current state of operations in order to plan future improvements. In this study, we propose an improvement model based on DMAIC with VSM 4.0 for a truck cooler manufacturer to improve the picking workstation design with a human-centered approach. We use the DMAIC method to analyze the project step by step. After identifying the root cause, we identified countermeasures to improve the productivity. To reduce human error, the project team adopted a human-centered approach and applied lean tools, such as visual management, error prevention, and waste analysis. As a result of this case study, the yield rate was improved from 98% to 100%, and the direct savings of the project amounted to EUR 3180, mainly due to the freeing up of space. A human-centered LSS framework is also presented as a novel contribution of this study.
... Over the past ten years, the approach to business management around the world has undergone a profound change. To combat the politico-economically unstable environment, organizations have sought to find new ways and means of responding based on knowledge, market research, and study, as well as creating and adapting to new work methodologies through metrics-driven management [1,2]. Organizational survival depends on the construction and integration of knowledge promoting adaptation and stimulation of the environment, as well as change through the firm's knowledge and practices [3]. ...
... Lean tools involve all employees positively, through change, and in creating value for the customer. At the same time, it means that there will be fewer errors and more efficient and methodical workflows [2]. ...
The organizations of horticultural producers and, particularly, those that deal with extremely perishable endogenous fruits, such as peaches and cherries, have a greater need to optimize production flows and processes. A particularity of the horticultural industry is the short shelf life of raw materials and the seasonality of products. In this paper, optimization techniques are used to improve the production flows and the management of cold storage and distribution in a fruit central. The application of Lean tools allowed reducing the cycle time by 4.37 min and the lead time by 7.10 min of the whole process, i.e., a reduction of 35.5% and 10.6% of the cycle time and lead time, respectively, excluding the cold conservation operation. The study shows that it is possible to reduce, or even eliminate, waste throughout the process, reduce unnecessary movement, adapt the layout, maximize workspace, and level stocks, as well as greater supplier involvement in a continuous improvement approach. This approach can be outlined as a good practice for the optimization of productive flows and management logistics that may benefit productivity, energy efficiency, human resources distribution, food quality, and reduce food waste.
... Organizations show their environmental commitment by showing effort toward sustainability, and sometimes it becomes easily visible to the customer. For instance, one of the leading coffee brands switch their lighting with smart LEDs and also installed a smart water-efficient fixture that caught the customers' eye as it signals the customer about the retailers' commitment to environmental sustainability (Marques et al., 2021). However, an organization larger in size is more open to new opportunities and investments, which makes it easier for them to invest in comparison to a small organization. ...
Purpose
Businesses are increasingly striving to become sustainable in terms of economic, environmental and social aspects. However, in the fresh food retail supply chains (SCs), achieving environmental objectives can be challenging because of the unique characteristics of products such as perishability, bulkiness, short product lifecycle and the requirement for cold chain infrastructure. The retail industry is the face of a SC. Therefore, its role in achieving sustainable objectives is pivotal. This study examines the effect of green in-store operations on sustainability performance indicators of fresh food retail and examines the moderating role of organization size in this context.
Design/methodology/approach
Data are collected through surveys using self-administered questionnaires from 70 retail stores with 188 completed responses. Data are analyzed using structural equation modeling.
Findings
Results show a positive relationship between green in-store operation with environmental social and economic performance. Furthermore, these relationships are moderated by the organization size such that the positive green in-store operation and performance relationships are stronger in the case of environmental and social performance only and for larger retail stores. No moderation is seen for economic performance.
Originality/value
The study broadens the understanding of green SC management’s effect on sustainability performance in the retail industry. It shows how the positive implications of a green SC are contingent on organization size and have prominence for environmental and social performance.
