THE ROLE OF LEAN MANUFACTURING IN ENHANCING OPERATIONAL EFFICIENCY AND WASTE REDUCTION
DOI:
https://doi.org/10.62207/ej0qp907Keywords:
Lean Manufacturing, Artificial Intelligence, Internet of Things, Operational Efficiency, Waste Reduction, High VariabilityAbstract
The application of Lean Manufacturing has long been recognized as an effective method for increasing operational efficiency and reducing waste in the manufacturing industry. However, in production environments with high variability, there is still a gap in understanding the role of digital technology integration, such as Artificial Intelligence (AI) and the Internet of Things (IoT), in strengthening Lean implementation. This research aims to explore the impact of integrating AI and IoT within a Lean Manufacturing framework on operational efficiency and waste reduction, especially in diverse production conditions. Using a systematic literature review approach with the PRISMA method, data was collected from various international databases, including Scopus and IEEE Xplore. The research results show that the integration of AI and IoT can improve real-time error detection, minimize downtime, and optimize resource utilization more efficiently. These findings provide practical implications for industries facing high variability to adopt digital technologies to strengthen Lean strategies and drive sustainable competitiveness.
References
Ali, B. (2023). Internet of things-assisted vehicle route optimization for municipal solid waste collection. Applied Sciences, 14(1), 287. https://doi.org/10.3390/app14010287
Argiyantari, B., Simatupang, T., & Basri, M. (2020). Pharmaceutical supply chain transformation through application of the lean principle: a literature review. Journal of Industrial Engineering and Management, 13(3), 475. https://doi.org/10.3926/jiem.3100
Ayoubi, H. (2023). Artificial intelligence in green management and the rise of digital lean for sustainable efficiency. E3s Web of Conferences, 412, 01053. https://doi.org/10.1051/e3sconf/202341201053
Bakhar, M. (2023). Impact analysis of the use of iot technology and environmental monitoring systems on waste reduction in the food and beverage industry in indonesia. West Science Interdisciplinary Studies, 1(11), 1213-1220. https://doi.org/10.58812/wsis.v1i11.380
Baldini, E., Chessa, S., & Brogi, A. (2023). Estimating the environmental impact of green iot deployments. Sensors, 23(3), 1537. https://doi.org/10.3390/s23031537
Barari, A., Tsuzuki, M., Cohen, Y., & Macchi, M. (2021). Editorial: intelligent manufacturing systems towards industry 4.0 era. Journal of Intelligent Manufacturing, 32(7), 1793-1796. https://doi.org/10.1007/s10845-021-01769-0
Buer, S., Semini, M., Strandhagen, J., & Sgarbossa, F. (2020). The complementary effect of lean manufacturing and digitalisation on operational performance. International Journal of Production Research, 59(7), 1976-1992. https://doi.org/10.1080/00207543.2020.1790684
Çakır, A., Akın, Ö., Deniz, H., & Yılmaz, A. (2022). Enabling real time big data solutions for manufacturing at scale. Journal of Big Data, 9(1). https://doi.org/10.1186/s40537-022-00672-6
Dmitrieva, E. (2024). Iot and ai integration: an experiment on smart manufacturing efficiency in industry 5.0. Bio Web of Conferences, 86, 01062. https://doi.org/10.1051/bioconf/20248601062
Florescu, A. and Barabas, S. (2022). Development trends of production systems through the integration of lean management and industry 4.0. Applied Sciences, 12(10), 4885. https://doi.org/10.3390/app12104885
Ghelani, H. (2021). Advances in lean manufacturing: improving quality and efficiency in modern production systems. International Journal of Scientific Research and Management, 9(06), 611-625. https://doi.org/10.18535/ijsrm/v9i06.ec02
Ghobadian, A., Talavera, I., Bhattacharya, A., Kumar, V., Garza‐Reyes, J., & O’Regan, N. (2020). Examining legitimatisation of additive manufacturing in the interplay between innovation, lean manufacturing and sustainability. International Journal of Production Economics, 219, 457-468. https://doi.org/10.1016/j.ijpe.2018.06.001
Ghosh, M. (2012). Lean manufacturing performance in indian manufacturing plants. Journal of Manufacturing Technology Management, 24(1), 113-122. https://doi.org/10.1108/17410381311287517
Khan, A., Laghari, A., Dootio, M., & Karim, S. (2023). The collaborative role of blockchain, artificial intelligence, and industrial internet of things in digitalization of small and medium-size enterprises. Scientific Reports, 13(1). https://doi.org/10.1038/s41598-023-28707-9
manufacturing tools and digital technologies. International Journal of Mathematical Engineering and Management Sciences, 5(5), 851-868. https://doi.org/10.33889/ijmems.2020.5.5.066
Narula, S., Puppala, H., Luthra, S., Dwivedy, M., Prakash, S., & Talwar, V. (2022). Are industry 4.0 technologies enablers of lean? evidence from manufacturing industries. International Journal of Lean Six Sigma, 14(1), 115-138. https://doi.org/10.1108/ijlss-04-2021-0085
Nordin, N., Deros, B., & Wahab, D. (2014). Lean manufacturing implementation in malaysian automotive industry: an exploratory study. Operations and Supply Chain Management an International Journal, 21-30. https://doi.org/10.31387/oscm090053
Núñez-Merino, M., Marín, J., Fuentes, J., & Martínez‐Jurado, P. (2020). Information and digital technologies of industry 4.0 and lean supply chain management: a systematic literature review. International Journal of Production Research, 58(16), 5034-5061. https://doi.org/10.1080/00207543.2020.1743896
Ooi, Y., Ng, T., & Cheong, W. (2023). Implementing industry 4.0 and lean practices for business performance in manufacturing: case of malaysia. International Journal of Advanced and Applied Sciences, 10(3), 143-156. https://doi.org/10.21833/ijaas.2023.03.019
Palanisamy, C. (2023). Smart manufacturing with smart technologies – a review. International Journal on Robotics Automation and Sciences, 5(2), 85-88. https://doi.org/10.33093/ijoras.2023.5.2.10
Petrillo, A., Caiazzo, B., Piccirillo, G., Santini, S., & Murino, T. (2022). An iot-based and cloud-assisted ai-driven monitoring platform for smart manufacturing: design architecture and experimental validation. Journal of Manufacturing Technology Management, 34(4), 507-534. https://doi.org/10.1108/jmtm-02-2022-0092
Pratama, W., Yanuar, A., & Rendra, M. (2019). Proposed improvement to minimize motion waste in production of head casing parts at pt. multi instrumentation with lean manufacturing approach. Quantum Teknika Journal of Applied Mechanical Engineering, 1(1). https://doi.org/10.18196/jqt.010106
Rahamneh, A., Alrawashdeh, S., Bawaneh, A., Alatyat, Z., Mohammad, A., Mohammad, A., … & Al‐Hawary, S. (2023). The effect of digital supply chain on lean manufacturing: a structural equation modelling approach. Uncertain Supply Chain Management, 11(1), 391-402. https://doi.org/10.5267/j.uscm.2022.9.003
Rao, K. (2024). Transformative applications of iot in diverse industries: a mini review. Malaysian Journal of Science and Advanced Technology, 130-140. https://doi.org/10.56532/mjsat.v4i2.292
Rosin, F., Forget, P., Lamouri, S., & Pellerin, R. (2019). Impacts of industry 4.0 technologies on lean principles. International Journal of Production Research, 58(6), 1644-1661. https://doi.org/10.1080/00207543.2019.1672902
Saad, S., Bhovar, C., Bahadori, R., & Zhang, H. (2021). Industry 4.0 application in lean manufacturing – a systematic review.. https://doi.org/10.3233/atde210059
Saboo, A., Reyes, J., Er, A., & Kumar, V. (2014). A vsm improvement-based approach for lean operations in an indian manufacturing sme. International Journal of Lean Enterprise Research, 1(1), 41. https://doi.org/10.1504/ijler.2014.062281
Santhosh, N., Srinivsan, M., & Ragupathy, K. (2020). Internet of things (iot) in smart manufacturing. Iop Conference Series Materials Science and Engineering, 764(1), 012025. https://doi.org/10.1088/1757-899x/764/1/012025
Saqlain, M., Piao, M., Shim, Y., & Lee, J. (2019). Framework of an iot-based industrial data management for smart manufacturing. Journal of Sensor and Actuator Networks, 8(2), 25. https://doi.org/10.3390/jsan8020025
Solheim, A. and Powell, D. (2020). A learning roadmap for digital lean manufacturing., 417-424. https://doi.org/10.1007/978-3-030-57997-5_48
Trubetskaya, A., Ryan, A., & Murphy, F. (2023). An implementation model for digitisation of visual management to develop a smart manufacturing process. International Journal of Lean Six Sigma, 15(8), 32-49. https://doi.org/10.1108/ijlss-07-2022-0156
Valamede, L. and Akkari, A. (2020). Lean 4.0: a new holistic approach for the integration of lean
Wang, Y. (2024). Research on sustainable green building space design model integrating iot technology. Plos One, 19(4), e0298982. https://doi.org/10.1371/journal.pone.0298982
Wofuru-Nyenke, O. (2021). Value stream mapping: a tool for waste reduction. International Journal of Innovative Research and Development, 10(6). https://doi.org/10.24940/ijird/2021/v10/i6/jun21009
Zhang, K., Qu, T., Zhou, D., Thürer, M., Liu, Y., Nie, D., … & Huang, G. (2018). Iot-enabled dynamic lean control mechanism for typical production systems. Journal of Ambient Intelligence and Humanized Computing, 10(3), 1009-1023. https://doi.org/10.1007/s12652-018-1012-z
Downloads
Published
Issue
Section
License
Copyright (c) 2024 Degdo Suprayitno (Author)

This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.

















