This study investigates the application of Lean methodologies within the context of Mass Customization (MC) in order to enhance operational efficiencies in manufacturing, specifically examining Dieci’s production line and its Supply Chain. Mass Customization is becoming increasingly essential as companies around the world strive to meet individualized customer demands while maintaining cost-effectiveness in record Lead Time. By implementing a structured Lean assessment tool on Dieci’s production line 5, this research provides a comprehensive analysis of Lean's impact on MC production processes, as well as a way to pinpoint exactly the areas to improve, strengthened with separate data extraction method. The study follows a mixed-methods approach, encompassing three phases: quantitative data extraction and KPI evaluation for Lean , Evaluation of the mass customization level of the company, and finally, a correlative qualitative on-ground observations. The results demonstrate a significant correlation between the data extraction result and their statistical analysis and behaviour compared to the lean assessment tool developed and answered through expert opinion. In that sense, the study succeeds in finding similar results from both qualitative and quantitative methods; Ensuring thus what areas to improve and what KPIs to monitor and work on in order to improve said area. The findings also highlight challenges related to tardiness, data synchronization, and the need for a dedicated Continuous Improvement Specialist. These limitations suggest that while Lean principles contribute positively to MC, full optimization may require more robust, adaptable systems and an integrated approach. Future developments are proposed, including advanced monitoring systems and a real-time data feedback loop, as well as a role dedicated to continuous improvement, ensuring sustainable efficiency gains. This research contributes with a Lean assessment model tailor-fit for mass customization plants, addressing specific demands within MC environments and paving the way for more responsive, efficient production strategies.
Questo studio indaga sull'applicazione delle metodologie Lean nel contesto della Mass Customization (MC) per migliorare l'efficienza operativa nella produzione, esaminando in particolare la linea di produzione e la Supply Chain di Dieci. La Mass Customization sta diventando sempre più essenziale, poiché le aziende di tutto il mondo cercano di soddisfare le esigenze individuali dei clienti mantenendo la convenienza economica e riducendo i tempi di consegna. Implementando uno strumento strutturato di valutazione Lean sulla linea di produzione 5 di Dieci, questa ricerca fornisce un'analisi completa dell'impatto del Lean sui processi di produzione MC, oltre a un metodo per individuare con precisione le aree da migliorare, rafforzato da un metodo separato di estrazione dei dati. Lo studio segue un approccio a metodi misti, articolato in tre fasi: estrazione quantitativa dei dati e valutazione dei KPI per il Lean, valutazione del livello di mass customization dell'azienda, e infine osservazioni qualitative sul campo. I risultati dimostrano una significativa correlazione tra l'analisi dei dati estratti e il loro comportamento statistico rispetto allo strumento di valutazione Lean sviluppato e completato tramite opinioni di esperti. In questo senso, lo studio riesce a ottenere risultati simili dai metodi qualitativi e quantitativi, identificando così le aree da migliorare e i KPI da monitorare e su cui lavorare per migliorare tali aree. I risultati evidenziano anche sfide legate ai ritardi, alla sincronizzazione dei dati e alla necessità di uno Specialista dedicato al Miglioramento Continuo. Queste limitazioni suggeriscono che, sebbene i principi Lean contribuiscano positivamente alla MC, l'ottimizzazione completa potrebbe richiedere sistemi più robusti e adattabili e un approccio integrato. Sono proposti sviluppi futuri, tra cui sistemi avanzati di monitoraggio e un feedback in tempo reale dei dati, nonché un ruolo dedicato al miglioramento continuo, per garantire guadagni di efficienza sostenibili. Questa ricerca contribuisce con un modello di valutazione Lean su misura per impianti di mass customization, rispondendo alle specifiche esigenze degli ambienti MC e aprendo la strada a strategie di produzione più reattive ed efficienti.
Lean identification in the context of mass customization, case study: Dieci
Jebir, Halim
2023/2024
Abstract
This study investigates the application of Lean methodologies within the context of Mass Customization (MC) in order to enhance operational efficiencies in manufacturing, specifically examining Dieci’s production line and its Supply Chain. Mass Customization is becoming increasingly essential as companies around the world strive to meet individualized customer demands while maintaining cost-effectiveness in record Lead Time. By implementing a structured Lean assessment tool on Dieci’s production line 5, this research provides a comprehensive analysis of Lean's impact on MC production processes, as well as a way to pinpoint exactly the areas to improve, strengthened with separate data extraction method. The study follows a mixed-methods approach, encompassing three phases: quantitative data extraction and KPI evaluation for Lean , Evaluation of the mass customization level of the company, and finally, a correlative qualitative on-ground observations. The results demonstrate a significant correlation between the data extraction result and their statistical analysis and behaviour compared to the lean assessment tool developed and answered through expert opinion. In that sense, the study succeeds in finding similar results from both qualitative and quantitative methods; Ensuring thus what areas to improve and what KPIs to monitor and work on in order to improve said area. The findings also highlight challenges related to tardiness, data synchronization, and the need for a dedicated Continuous Improvement Specialist. These limitations suggest that while Lean principles contribute positively to MC, full optimization may require more robust, adaptable systems and an integrated approach. Future developments are proposed, including advanced monitoring systems and a real-time data feedback loop, as well as a role dedicated to continuous improvement, ensuring sustainable efficiency gains. This research contributes with a Lean assessment model tailor-fit for mass customization plants, addressing specific demands within MC environments and paving the way for more responsive, efficient production strategies.| File | Dimensione | Formato | |
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https://hdl.handle.net/10589/230417