Skip to main content

Abstract

Lean Production Systems are enterprise-specific, methodical frameworks for the continuous orientation of all enterprise processes to the customer in order to achieve overall objectives. Due to the increasing complexity of digital transformation, the management of methods in Lean Production Systems 4.0 (LPS 4.0) is a challenging task for industrial engineering practice. Starting with a set of 35 Lean methods, this paper aim to review the existing literature regarding digitally-advanced LPS 4.0 methods. Academic contributions were analyzed in a systematic literature review (SLR). The SLR screening of 706 scientific papers led to the identification of 54 approaches for LPS 4.0 methods. All 54 approaches were assessed regarding their maturity level for detailed documentation. As a result, 18 LPS 4.0 methods are described in a uniform standardized LPS 4.0 method template. The new LPS 4.0 methods are highly relevant for practical application in industrial engineering practice, which has already been tested in a first implementation of methods in an industrial engineering toolbox (Toolbox Lean 4.0).

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 149.00
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Hardcover Book
USD 199.99
Price excludes VAT (USA)
  • Durable hardcover edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

References

  1. VDI : Lean Production Systems: Basic Principles, Introduction, and Review (2870 Part 1) (2012)

    Google Scholar 

  2. Dombrowski, U., Richter, T., Krenkel, P.: Interdependencies of industrie 4.0 & lean production systems. Procedia Manufacturing 11, 1061–1068 (2017). https://doi.org/10.1016/j.promfg.2017.07.217

    Article  Google Scholar 

  3. Deuse, J., Dombrowski, U., Nöhring, F., et al.: Systematic combination of Lean Management with digitalization to improve production systems on the example of Jidoka 4.0. Int. J. Eng. Bus. Mgmt. 12, 1–9 (2020). https://doi.org/10.1177/1847979020951351

    Article  Google Scholar 

  4. Richter, T.: Vorgehensmodell zur Implementierung von Industrie 4.0 im Kontext Ganzheitlicher Produktionssysteme. Dissertation. Schriftenreihe des IFU, vol 37. Shaker, Düren (2021)

    Google Scholar 

  5. Dombrowski, U., Krenkel, P.: Ganzheitliches Produktionsmanagement. Springer, Berlin Heidelberg, Berlin, Heidelberg (2021)

    Book  Google Scholar 

  6. Schumacher, S., Hall, R., Bildstein, A., et al.: Lean production systems 4.0: systematic literature review and field study on the digital transformation of lean methods and tools. Int. J. Prod. Res., 1–23 (2022). https://doi.org/10.1080/00207543.2022.2159562

  7. Baudin, M., Netland, T.: Introduction to Manufacturing: An Industrial Engineering and Management Perspective. Routledge, New York (2023)

    Google Scholar 

  8. Schumacher, S., Hall, R., Bildstein, A., et al.: Toolbox lean 4.0 - development and implementation of a database approach for the management of digital methods and tools. Procedia CIRP 107, 776–781 (2022). https://doi.org/10.1016/j.procir.2022.05.061

    Article  Google Scholar 

  9. Dombrowski, U., Richter, T.: The lean production system 4.0 framework. In: Moon, I., Lee, G.M., Park, J., et al. (eds) Advances in Production Management Systems, 536. Springer Int. Publ., Cham, pp. 410–416 (2018)

    Google Scholar 

  10. Fink, A.: Conducting Research Literature Reviews: From the Internet to Paper. Sage, Los Angeles (2020)

    Google Scholar 

  11. VDI: Lean Production Systems: List of Methods (2870 Part 2) (2013)

    Google Scholar 

  12. Nyhuis, P., Heins, M., Pachow-Frauenhofer, J., et al.: Wandlungsfähige Produk-tionssysteme. ZWF 103, 333–337 (2008). https://doi.org/10.3139/104.101285

    Article  Google Scholar 

  13. Taylor, F.W.: The Principles of Scientific Management. Harper & Brothers, New York, London (1911)

    Google Scholar 

  14. Spath, D.: Ganzheitlich produzieren: Innovative Organisation und Führung. LOG_X Verlag, Wiesbaden (2003)

    Google Scholar 

  15. Ōno, T.: Toyota Production System. Productivity Press, New York (1988)

    Google Scholar 

  16. Womack, J.P., Jones, D.T.: Lean Thinking. Free Press, New York (2003)

    Google Scholar 

  17. Womack, J.P., Jones, D.T., Roos, D.: The Machine that Changed the World: Based on the Massachusetts Institute of Technology 5 Million Dollar 5 Year Study on the Future of the Automobile. Rawson, New York (1990)

    Google Scholar 

  18. Liker, J.K.: The Toyota Way: 14 Management Principles from the World’s Greatest Manufacturer, 2nd edn. McGraw-Hill; EBSCO Publ, New York, Ibswich Mass (2021)

    Google Scholar 

  19. Shah, R., Ward, P.T.: Defining and developing measures of lean production. J. Oper. Mgmt. 25, 785–805 (2007). https://doi.org/10.1016/j.jom.2007.01.019

    Article  Google Scholar 

  20. Kagermann, H., Wahlster, W.: Ten years of industrie 4.0. Sci. 4, 26 (2022). https://doi.org/10.3390/sci4030026

  21. Bauer, D., Schumacher, S., Gust, A., et al.: Characterization of autonomous production by a stage model. Procedia CIRP 81, 192–197 (2019). https://doi.org/10.1016/j.procir.2019.03.034

    Article  Google Scholar 

  22. Neugebauer, R.: Digital Transformation. Fraunhofer-Forschungsfokus. Springer Vieweg, Berlin (2019)

    Google Scholar 

  23. Schumacher, S., Schmid, F., Bildstein, A., et al.: Lean production systems 4.0: the impact of the digital transformation on production system levels. In: 54th CIRP Conference on Manufacturing Systems. Procedia CIRP 104, pp. 259–264 (2021). https://doi.org/10.1016/j.procir.2021.11.044

  24. Meudt, T., Metternich, J., Abele, E.: Value stream mapping 4.0. CIRP Ann. 66, 413–416 (2017). https://doi.org/10.1016/j.cirp.2017.04.005

    Article  Google Scholar 

  25. Romero, D., Gaiardelli, P., Powell, D., et al.: Digital lean cyber-physical production systems: the emergence of digital lean manufacturing and the significance of digital waste. In: Moon, I., Lee, G.M., Park, J., et al. (eds) Advances in Production Management Sys-tems. Production Management for Data-Driven, Intelligent, Collaborative, and Sustainable Manufacturing: IFIP WG 5.7 International Conference, APMS 2018, Seoul, Korea, Au-gust 26–30, 2018, Proceedings, Part I. Springer International Publishing, Cham, pp. 11–20 (2018)

    Google Scholar 

  26. Rosin, F., Forget, P., Lamouri, S., et al.: Impacts of industry 4.0 technologies on lean principles. Int. J. Prod. Res. 58, 1644–1661 (2020). https://doi.org/10.1080/00207543.2019.1672902

    Article  Google Scholar 

  27. Rossini, M., Costa, F., Tortorella, G.L., et al.: Lean Production and industry 4.0 integration: how lean Automation is emerging in manufacturing industry. Int. J. Prod. Res., 1–21 (2021). https://doi.org/10.1080/00207543.2021.1992031

  28. Tortorella, G.L., Fettermann, D., Cauchick Miguel, P.A., et al.: Learning organisation and lean production: an empirical research on their relationship. Int. J. Prod. Res. 58, 3650–3666 (2020). https://doi.org/10.1080/00207543.2019.1633028

    Article  Google Scholar 

  29. Lorenz, R., Buess, P., Macuvele, J., et al.: Lean and digitalization - contradictions or complements? In: Ameri, F., Stecke, K.E., von Cieminski, G., et al. (eds.) Advances in Produc-tion Management Systems. Springer Int, vol. 566, pp. 77–84. Publ, Cham (2019)

    Google Scholar 

  30. Dolgui, A., Bernard, A., Lemoine, D., et al.: Advances in production management systems. Artificial Intelligence for Sustainable and Resilient Production Systems. IFIP Advances in Information and Communication Technology. Springer International Publishing, Cham (2021)

    Google Scholar 

  31. Ciano, M.P., Dallasega, P., Orzes, G., et al.: One-to-one relationships between Industry 4.0 technologies and lean production techniques: a multiple case study. Int. J. Prod. Res. 59, 1386–1410 (2021). https://doi.org/10.1080/00207543.2020.1821119

    Article  Google Scholar 

  32. Buer, S.-V., Semini, M., Strandhagen, J.O., et al.: The complementary effect of lean manufacturing and digitalisation on operational performance. Int. J. Prod. Res. 59, 1976–1992 (2021). https://doi.org/10.1080/00207543.2020.1790684

    Article  Google Scholar 

  33. Langlotz, P., Aurich, J.C.: Causal and temporal relationships within the combination of lean production systems and industry 4.0. Procedia CIRP 96, 236–241 (2021). https://doi.org/10.1016/j.procir.2021.01.080

    Article  Google Scholar 

  34. Hines, P., Tortorella, G.L., Antony, J., et al.: Lean industry 4.0: past, present, and future. Qual. Manag. J. 30, 64–88 (2023). https://doi.org/10.1080/10686967.2022.2144786

    Article  Google Scholar 

  35. Mittal, S., Khan, M.A., Purohit, J.K., et al.: A smart manufacturing adoption framework for SMEs. Int. J. Prod. Res. 58, 1555–1573 (2020). https://doi.org/10.1080/00207543.2019.1661540

    Article  Google Scholar 

  36. Jungkind, W., Könneker, M., Pläster, I., et al.: Handbuch der Prozessoptimierung: Die richtigen Werkzeuge auswählen und zielsicher einsetzen, 1. Auflage. REFA-Kompendium Arbeits organisation, Band 2. Hanser, München (2018)

    Google Scholar 

  37. Ullmann, G.: Ganzheitliche Produktionssysteme: IPH-Methodensammlung (2009). https://www.iph-hannover.de/_media/files/downloads/IPH_Lean_Methodensammlung.pdf. Accessed 12 Mar 2023

  38. Torraco, R.J.: Writing integrative literature reviews. HR Development Rev. 15, 404–428 (2016). https://doi.org/10.1177/1534484316671606

    Article  Google Scholar 

  39. Warschat, J., Schimpf, S., Korell, M. (eds.): Technologien frühzeitig erkennen. Fraunhofer-Verlag, Stuttgart, Nutzen-potenziale systematisch bewerten (2015)

    Google Scholar 

  40. Rummel, S.: Eine bewertungsbasierte Vorgehensweise zur Tauglichkeitsprüfung von Technologiekonzepten in der Technologieentwicklung. Schriftenreihe zu Arbeitswissen-schaft und Technologiemanagement, vol 16. Universitätsbibliothek der Universität Stuttgart, Stuttgart (2015)

    Google Scholar 

  41. Antes, G., von Elm, E.: Das PRISMA-Statement - was sollte über systematische Ub-ersichtsarbeiten berichtet werden? (The PRISMA Statement - what should be reported about systematic reviews?). Dtsch Med Wochenschr 134, 1619 (2009). https://doi.org/10.1055/s-0029-1233989

    Article  Google Scholar 

  42. Moher, D., Liberati, A., Tetzlaff, J., et al.: Preferred reporting items for systematic reviews and meta-analyses: the PRISMA statement. PLoS Med 6, e1000097 (2009). https://doi.org/10.1371/journal.pmed.1000097

    Article  Google Scholar 

  43. Liberati, A., Altman, D.G., Tetzlaff, J., et al.: The PRISMA statement for reporting systematic reviews and meta-analyses of studies that evaluate health care interventions: explanation and elaboration. PLoS Med 6 (2009). https://doi.org/10.1371/journal.pmed.1000100

  44. Becker, J., Knackstedt, R., Pöppelbuß, J.: Entwicklung von Reifegradmodellen für das IT-Management. Wirtsch Inform 51, 249–260 (2009). https://doi.org/10.1007/s11576-009-0167-9

    Article  Google Scholar 

  45. Mettler, T.: Supply-Management im Krankenhaus: Konstruktion und Evaluation eines konfigurierbaren Reifegradmodells zur zielgerichteten Gestaltung. Sankt Gallen, Univ., Diss., 2010, Sierke (2010)

    Google Scholar 

  46. Schumacher, S., Hall, R., Hautzinger, M., et al.: LPS 4.0 Methods Catalogue: Attachment to the Paper “Characterization of Digitalized Methods in Lean Production Systems 4.0” (2023). https://owncloud.fraunhofer.de/index.php/s/m7dqQSWvJVihLiS. Accessed 25 Mar 2023

  47. Röltgen, A.T., Bernardy, V., Müller, R., et al.: Entwicklung, Einsatz und Evaluation eines Tools für digitales Ideenmanagement. Ein Fallbeispiel. Gr Interakt Org 51, 49–58 (2020). https://doi.org/10.1007/s11612-020-00500-6

    Article  Google Scholar 

  48. Stadnicka, D., Bonci, A., Lorenzoni, E., et al.: Symbiotic cyber-physical kanban 4.0: an approach for SMEs. In: 2020 25th IEEE International Conference on Emerging Technologies and Factory Automation (ETFA). IEEE, pp. 140–147 (2020)

    Google Scholar 

  49. Lopez-Leyva, J.A., Molina-Inzunza, A., Navarro-Paz, P., et al.: Customized smart andon system to improve the efficiency of industrial departments. JSIR 79, 35–37 (2020). https://doi.org/10.56042/jsir.v79i1.68111

  50. Frick, N., Metternich, J.: The Digital Value Stream Twin. Systems 10, 102 (2022). https://doi.org/10.3390/systems10040102

  51. Qiuling, Y.: Innovative practice of digital audit management mode for power grid enterprises. In: 2021 International Conference on Control Science and Electric Power Systems (CSEPS). IEEE, pp. 238–241 (2021)

    Google Scholar 

  52. Aufleger, M., Schneider, M.: Cardboard engineering 4.0 – IIoT für jedermann? ZWF 115, 442–445 (2020). https://doi.org/10.3139/104.112361

    Article  Google Scholar 

  53. Schäfer, F., Mayr, A., Hess, A., et al.: Six sigma 4.0. ZWF 114, 140–144 (2019). https://doi.org/10.3139/104.112047

    Article  Google Scholar 

  54. Cooke, T.A., Howe, W.R.: Dynamic statistical process control limits for power quality trend data. In: 2018 18th International Conference on Harmonics and Quality of Power (ICHQP). IEEE, pp. 1–5 (2018)

    Google Scholar 

  55. Adriano, D.D., Montez, C., Novaes, A.G.N., et al.: DMRVR: dynamic milk-run vehicle routing solution using fog-based vehicular ad hoc networks. Electronics 9, 2010 (2020). https://doi.org/10.3390/electronics9122010

    Article  Google Scholar 

  56. Xu, Y., Chen, M.: Improving just-in-time manufacturing operations by using internet of things based solutions. Procedia CIRP 56, 326–331 (2016). https://doi.org/10.1016/j.procir.2016.10.030

    Article  Google Scholar 

  57. Longard, L., Meißner, A., Müller, M., et al.: Digitales shopfloor management – wohin geht die reise? ZWF 115, 645–649 (2020). https://doi.org/10.3139/104.112358

    Article  Google Scholar 

  58. Peças, P., Encarnação, J., Gambôa, M., et al.: PDCA 4.0: a new conceptual approach for continuous improvement in the industry 4.0 paradigm. Applied Sci. 11, 7671 (2021). https://doi.org/10.3390/app11167671

  59. Romero, D., Gaiardelli, P., Powell, D.J., et al.: Intelligent poka-yokes: error-proofing and continuous improvement in the digital lean manufacturing world. In: Kim, D.Y., Cieminski, G., Romero, D. (eds) Advances in Production Management Systems. Smart Manufacturing and Logistics Systems: Turning Ideas into Action, 664. Springer Nature Switzerland, Cham, pp. 595–603 (2022)

    Google Scholar 

  60. Doğan, O., Cebeci, U., Oksuz, M.K.: An intelligent decision support system for SMED and its application in textile industry. In: Proceedings of the International Conference on Industrial Engineering and Operations Management (2018)

    Google Scholar 

  61. Kjellsen, H.S., Ramillon, Q.J.L., Dreyer, H.C., et al.: Heijunka 4.0 – key enabling technologies for production levelling in the process industry. In: Dolgui, A., Bernard, A., Lemoine, D., et al. (eds) Advances in Production Management Systems. Artificial Intelligence for Sustainable and Resilient Production Systems, 630. Springer International Publishing, Cham, pp. 704–711 (2021)

    Google Scholar 

  62. Alieva, J., Haartman, R.: Digital muda - the new form of waste by industry 4.0. OSCM: An Int J. 13(3), 269–278 (2020). https://doi.org/10.31387/OSCM0420268

  63. Valamede, L.S., Akkari, A.C.S.: Lean 4.0: A new holistic approach for the integration of lean manufacturing tools and digital technologies. Int J Math, Eng, Manag Sci. 5, 851–868 (2020). https://doi.org/10.33889/IJMEMS.2020.5.5.066

Download references

Acknowledgements

This work was supported by the German Federal Ministry of Education and Research (BMBF) under grant 02L16Y101 (Future Work Lab) and implemented by the Project Management Agency Karlsruhe (PTKA).

Credit Author Statement

Simon Schumacher – Conceptualization, methodology, writing – original draft.

Roland Hall – Conceptualization, methodology, writing – reviewing and editing.

Michael Hautzinger – Conceptualization, methodology, writing – original draft.

Jan Schöllmann – Visualization, writing – reviewing and editing.

Thomas Bauernhansl – Supervision, writing – review and editing.

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Simon Schumacher .

Editor information

Editors and Affiliations

Rights and permissions

Reprints and permissions

Copyright information

© 2023 IFIP International Federation for Information Processing

About this paper

Check for updates. Verify currency and authenticity via CrossMark

Cite this paper

Schumacher, S., Hall, R., Hautzinger, M., Schöllmann, J., Bauernhansl, T. (2023). Characterization of Digitally-Advanced Methods in Lean Production Systems 4.0. In: Alfnes, E., Romsdal, A., Strandhagen, J.O., von Cieminski, G., Romero, D. (eds) Advances in Production Management Systems. Production Management Systems for Responsible Manufacturing, Service, and Logistics Futures. APMS 2023. IFIP Advances in Information and Communication Technology, vol 689. Springer, Cham. https://doi.org/10.1007/978-3-031-43662-8_14

Download citation

  • DOI: https://doi.org/10.1007/978-3-031-43662-8_14

  • Published:

  • Publisher Name: Springer, Cham

  • Print ISBN: 978-3-031-43661-1

  • Online ISBN: 978-3-031-43662-8

  • eBook Packages: Computer ScienceComputer Science (R0)

Publish with us

Policies and ethics