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A Framework for Using Dynamic Modeling to Support Lean Sustainment in a Complex Setting

This chapter proposes a framework for integrating lean and systems thinking tools to explore the dynamics of lean implementations in manufacturing. The value of this integrated approach is in supplementing the operational level principles of lean with the strategic outlook of systems thinking to mitigate adverse impacts of operational complexity on system performance. In particular, the focus of the framework is to enable the sustainment of lean gains in the long-term, a major challenge in manufacturing settings. The application of the framework is illustrated with a case study of a lean implementation for reducing work-in-process (WIP) at a clothing manufacturer dealing with a number of operational complexities such as demand uncertainty, a high product mix and inefficient processes. The case study highlights the usefulness of system dynamics modeling in revealing counterintuitive system behaviors that could compromise the success of the lean initiative. The simulation results demonstrate the application of the framework for sustaining lean implementations in practice. A Framework for Using Dynamic Modeling to Support Lean Sustainment in a Complex Setting: Illustrated With a Case Study From Manufacturing