Asian Journal of Engineering and Applied Technology (AJEAT)
Pivoting Lean Manufacturing through Industry 4.0 in the Indian ContextAuthor : Protik Basu and Pranab K. Dan
Volume 8 No.2 April-June 2019 pp 1-7
Industry 4.0 and lean management both focus on increasing productivity of industrial systems. Industry 4.0 is foreseen to revolutionize today’s manufacturing environment whereas lean management is an integrated techno-operational system which has gained increasing importance in recent times to bring about a competitive state in an organization. Though in the last three decades there have been rigorous studies on lean manufacturing (LM), its implementation in the Indian manufacturing domain is still in its nascent stage. A lack of research to explore the potential use of Industry 4.0 is also noted. Research work on the compatibility of Industry 4.0 with LM is scarce and any study on the role of Industry 4.0 on LM in the Indian manufacturing sector is practically unavailable. The aim of this research is to explore how the fourth industrial revolution, referred to as Industry 4.0, can strategize LM in the Indian manufacturing context. Empirical studies have disclosed that Indian managers are hesitant to go for automation and technological developments. Results of this work reveal that there needs to be a change in attitude and approach. Lean implementers in India need to embrace Industry 4.0 to pivot LM by automating through Cyber-Physical Systems and creating a flexible design and production model of customized and smart products.
Industry 4.0, Lean Manufacturing, Lean Implementation
 H. Lasi, P. Fettke, H. G. Kemper, T. Feld, and M. Hoffmann, “Industry 4.0”, Business & Information Systems Engineering, Vol. 6, No. 4, pp. 239-242, 2014.
 Encyclopedia Britannica website. [Online] Available at: https://www.britannica.com/event/Industrial-Revolution, 2004
 K. Zhou, T. Liu, and L. Zhou, “Industry 4.0: Towards future industrial opportunities and challenges”, in 12th IEEE International Conference on Fuzzy Systems and Knowledge Discovery(FSKD 2015), Zhangjiajie, China, pp. 2147-2152.
 J. Qin, Y. Liu, and R. Grosvenor, “A categorical framework of manufacturing for industry 4.0 and beyond”, Procedia CIRP, Vol. 52, pp. 173-178, 2016.
 T. Netland, “Industry 4.0: What about lean?”, Lean Management Journal-LMJ, Vol. 5, No. 2, pp. 22-23, 2015.
 R. Schmidt, M. Möhring, R. C., Härting, C. Reichstein, P. Neumaier, and P. Jozinović, “Industry 4.0-potentials for creating smart products: empirical research results”, in International Conference on Business Information Systems (BIS 2015), pp. 16-27, 2015.
 J. F. Krafcik, “Triumph of the lean production system”, MIT Sloan Management Review, Vol. 30, No. 1, pp. 41-52, 1988.
 A. Sanders, C. Elangeswaran, and J. Wulfsberg, “Industry 4.0 implies lean manufacturing: research activities in industry 4.0 function as enablers for lean manufacturing”, Journal of Industrial Engineering and Management, Vol. 9, No. 3, pp. 811-833, 2016.
 Y. Lu, “Industry 4.0: a survey on technologies, applications and open research issues”, Journal of Industrial Information Integration, Vol. 6, pp. 1-10, 2017.
 F. Almada-Lobo, “The Industry 4.0 revolution and the future of manufacturing execution systems (MES)”, Journal of Innovation Management, Vol. 3, No.4, pp. 16-21, 2016.
 E. D. Arnheiter, and J. Maleyeff, “The integration of lean management and Six Sigma”, The TQM magazine, Vol. 17, No. 1, pp. 5-18, 2005.
 D. Kolberg, and D. Zühlke, “Lean automation enabled by industry 4.0 technologies”, IFAC-PapersOnLine, Vol. 48, No. 3, pp. 1870-1875, 2015.
 A. Susilawati, J. Tan, D. Bell andM. Sarwar, “Fuzzy logic based method to measure degree of lean activity in manufacturing industry”, Journal of Manufacturing Systems, Vol. 34, pp. 1-11, 2015.
 M. D. Al-Tahat, and I. S. Jalham, “A structural equation model and a statistical investigation of lean-based quality and productivity improvement”, Journal of Intelligent Manufacturing, Vol. 26 No. 3, pp. 571-583, 2015.
 J. P. Womack, D. T. Jones, D. Roos, and D. S. Carpenter, The machine that changed the world, Rawson Associates, New York: Macmillan Publishing Company, 1990.
 J. P. Womack, and D. T. Jones, Lean Thinking: Banish Waste and Create Wealth in Your Corporation, New York: Free Press, 2003.
 T. Bendell, “A review and comparison of six sigma and the lean organizations”, The TQM magazine, Vol. 18, No. 3, pp. 255-262, 2006.
 M. Alsmadi, A. Almani, and R. Jerisat, “A comparative analysis of Lean practices and performance in the UK manufacturing and service sector firms”, Total Quality Management & Business Excellence, Vol. 23, No. 3-4, pp. 381-396, 2012.
 S. Vinodh, S. G. Gautham, and R. A. Ramiya, “Implementing lean sigma framework in an Indian automotive valves manufacturing organization: a case study”, Production Planning & Control, Vol. 22, No. 7, pp. 708-722, 2011.
 J. Bhamu, and K. Singh Sangwan, “Lean manufacturing: literature review and research issues”, International Journal of Operations & Production Management, Vol. 34, No.7, pp. 876-940, 2014.
 R. Shah, and P. T. Ward, “Lean manufacturing: context, practice bundles, and performance”, Journal of Operations Management, Vol. 21, No. 2, pp. 129-149, 2003.
 R. Shah, A. Chandrasekaran, K. Linderman, “In pursuit of implementation patterns: The context of lean and Six Sigma”, International Journal of Production Research, Vol. 46, No. 23, pp. 6679-6699, 2008.
 V. Kajdan, “Bumpy road to lean enterprise”, Total Quality Management, Vol. 19, Nos. 1-2, pp. 91-99, 2008.
 R. Chavez, W. Yu, M. Jacobs, B. Fynes, F. Wiengarten, and A. Lecuna, “Internal lean practices and performance: The role of technological turbulence”, International Journal of Production Economics, Vol. 160, pp. 157-171, 2015.
 H. Kagermann, W. Wahlster, and J. Helbig, “Recommendations for implementing the strategic initiative INDUSTRIE 4.0”, Final report of the Industrie 4.0 Working Group, acatech – National Academy of Science and Engineering, 2013.
 T. Stock, and G. Seliger, “Opportunities of sustainable manufacturing in industry 4.0”,Procedia CIRP 40, pp. 536-541, 2016.
 F. Shrouf, J. Ordieres, and G. Miragliotta, “Smart factories in Industry 4.0: A review of the concept and of energy management approached in production based on the Internet of Things paradigm”, in IEEE International Conference on Industrial Engineering and Engineering Management (IEEM 2014), pp. 697-701, 2014.
 N. Jazdi, “Cyber physical systems in the context of Industry 4.0”, in IEEE International Conference on Automation, Quality and Testing, Robotics, pp. 1-4, 2014.
 B. Mrugalska, and M. K. Wyrwicka, “Towards lean production in industry 4.0”, Procedia Engineering, Vol. 182, pp. 466-473, 2017.
 J. Lee, B. Bagheri, and H. A. Kao, “A cyber-physical systems architecture for industry 4.0-based manufacturing systems”, Manufacturing Letters, Vol. 3, pp. 18-23, 2015.
 J. Schlechtendahl, M. Keinert, F. Kretschmer, A. Lechler, and A.Verl, “Making existing production systems Industry 4.0-ready”, Production Engineering, Vol. 9, No. 1, pp. 143-148, 2015.
 B. Wang, J. Zhao, Z. Wan, J. Ma, H. Li, and J. Ma, “Lean Intelligent Production System and Value Stream Practice”, in DEStech Transactions on Economics, Business and Management, 3rd International Conference on Economics and Management (ICEM 2016), pp. 1-6, 2016.
 T. Wagner, C. Herrmann, and S. Thiede, “Industry 4.0 impacts on lean production systems”, Procedia CIRP, Vol. 63, pp. 125-131, 2017.
 A. Schumacher, S. Erol, and W. Sihn, “A maturity model for assessing industry 4.0 readiness and maturity of manufacturing enterprises”, Procedia CIRP, Vol. 52, pp. 161-166, 2016.
 V. Roblek, M. Meško, and A. Krapež, “A complex view of industry 4.0”, SAGE Open, Vol. 6, No. 2, pp. 1-11, 2016.
 D. Ivanov, A. Dolgui, B. Sokolov, F. Werner, and M. Ivanova, “A dynamic model and an algorithm for short-term supply chain scheduling in the smart factory industry 4.0” International Journal of Production Research, Vol. 54, No. 2, pp. 386-402, 2016.
 M. Rüßmann, M. Lorenz, P. Gerbert, M. Waldner, J. Justus, P. Engel, and M. Harnisch, “Industry 4.0: The future of productivity and growth in manufacturing industries”, Boston Consulting Group, Vol. 9,No. 1, pp. 54-89, 2015.
 C. Liu, and X. Xu, “Cyber-physical Machine Tool: The Era of Machine Tool 4.0”, Procedia CIRP, Vol. 63, pp. 70-75, 2017.
 G. Kube, and T. Rinn, “Industry 4.0: The next revolution in the industrial sector”,ZGK International, Vol. 67, No. 11, pp. 30–32, 2014.
 F. Baena, A. Guarin, J. Mora, J. Sauza, and S. Retat, “Learning Factory: The Path to Industry 4.0”, Procedia Manufacturing, Vol. 9, pp. 73-80, 2017.
 F. Long, P. Zeiler, and B. Bertsche, “Modelling the production systems in industry 4.0 and their availability with high-level Petri nets”, IFAC-PapersOnLine, Vol. 49, No. 12, pp. 145-150, 2016.
 H. Meissner, R. Ilsen, and J. C. Aurich, “Analysis of control architectures in the context of Industry 4.0”, Procedia CIRP, Vol. 62, pp. 165-169, 2017.
 C. Faller, and D. Feldmüller, “Industry 4.0 learning factory for regional SMEs”, Procedia CIRP, Vol. 32, pp. 88-91, 2015.
 S. So, and H. Sun, “An extension of IDT in examining the relationship between electronic-enabled supply chain integration and the adoption of lean production”, International Journal of Production Research, Vol. 49, No. 2, pp. 447-466, 2011.
 F. A. Abdulmalek, J. Rajgopal, and K. L. Needy, “A classification scheme for the process industry to guide the implementation of lean”, Engineering Management Journal, Vol. 18, No. 2, pp. 15-25, 2006.
 S. M. Zahraee, “A survey on lean manufacturing implementation in a selected manufacturing industry in Iran”, International Journal of Lean Six Sigma, Vol. 7, No. 2, pp. 136-148, 2016.
 Pullan, T. T., Bhasi, M., Madhu, G. “Decision support tool for lean product and process development. Production Planning & Control Vol. 24, No. 6, pp. 449-464, 2013.
 M. Houshmand, and B. Jamshidnezhad, “An extended model of design process of lean production systems by means of process variables”, Robotics and Computer-Integrated Manufacturing, Vol. 22, No. 1, pp. 1-16, 2006.
 M. Hoss, and C. S. ten Caten, “Lean schools of thought”, International Journal of Production Research, Vol. 51, No. 11, pp. 3270-3282, 2013.
 M. E. Bayou, and A. De Korvin, “Measuring the leanness of manufacturing systems: a case study of Ford Motor Company and General Motors”, Journal of Engineering and Technology Management, Vol. 25, No. 4, pp. 287-304, 2008.
 M. Eswaramoorthi, G. R. Kathiresan, P. S. S. Prasad, and P. V. Mohanram, “A survey on lean practices in Indian machine tool industries”, The International Journal of Advanced Manufacturing Technology, Vol. 52, Nos. 9-12, pp. 1091-1101, 2011.
 P. Basu, I. Ghosh, and P. K. Dan, “Structural equation modelling based empirical analysis of technical issues for lean manufacturing implementation in the Indian context” in 7th IEEE International Conference on Industrial Technology and Management (ICITM 2018), pp. 57-61, 2018.