Assessment of the Impact of Lean Tools on the Safety of the Shoemaking Industry

Detalhes bibliográficos
Autor(a) principal: Sá, José Carlos
Data de Publicação: 2023
Outros Autores: Soares, Leonardo, Dinis-Carvalho, José, Silva, Francisco, Santos, Gilberto
Tipo de documento: Artigo
Idioma: eng
Título da fonte: Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos)
Texto Completo: http://hdl.handle.net/10400.22/24783
Resumo: Both the Lean philosophy and occupational safety and health have been widely studied, although this has usually been carried out independently. However, the correlation between Lean and occupational safety and health in the industrial context is still underexplored. Indeed, Lean tools can be applied to ensure the best safety environment for workers in each kind of manufacturing process, and this deserves to be studied. The study described here aims to understand the influence of each of a set of four Lean tools used in an industrial context with a strong manual labor component, seeking to determine the influence of each of these Lean tools on the increase in safety obtained through their application. For this purpose, four Lean tools that are quite commonly applied are selected, taking into account previously presented work that pointed to the positive influence of the application of each of these tools on worker safety: total productive maintenance system, Gemba walk, visual management and Yokoten. This study aims to apply these Lean tools and to analyze their impact on productivity, and then, on the safety of a company selected as a target in order to validate the concept. For this purpose, a new tool is created. In the first instance, the tool analyzes the current state of the productive process and the safety level through the study of the risk levels detected in the plant. In terms of productivity results, a reduction between 7% and 12% in cycle time is achieved in four areas of the plant. The feedback from employees showed increased satisfaction with the processes’ simplification. To conclude, a 50% reduction in the number of work accidents per month is observed as a result of the implementation of Lean tools. The influence of the selected Lean tools on increasing both productivity and safety is clear, and our results prove the selection of tools to be largely adequate.
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spelling Assessment of the Impact of Lean Tools on the Safety of the Shoemaking IndustryGemba walkLean safetyorthopedic footweartotal productive maintenancevalue stream mappingoverall equipment effectivenessYokotenBoth the Lean philosophy and occupational safety and health have been widely studied, although this has usually been carried out independently. However, the correlation between Lean and occupational safety and health in the industrial context is still underexplored. Indeed, Lean tools can be applied to ensure the best safety environment for workers in each kind of manufacturing process, and this deserves to be studied. The study described here aims to understand the influence of each of a set of four Lean tools used in an industrial context with a strong manual labor component, seeking to determine the influence of each of these Lean tools on the increase in safety obtained through their application. For this purpose, four Lean tools that are quite commonly applied are selected, taking into account previously presented work that pointed to the positive influence of the application of each of these tools on worker safety: total productive maintenance system, Gemba walk, visual management and Yokoten. This study aims to apply these Lean tools and to analyze their impact on productivity, and then, on the safety of a company selected as a target in order to validate the concept. For this purpose, a new tool is created. In the first instance, the tool analyzes the current state of the productive process and the safety level through the study of the risk levels detected in the plant. In terms of productivity results, a reduction between 7% and 12% in cycle time is achieved in four areas of the plant. The feedback from employees showed increased satisfaction with the processes’ simplification. To conclude, a 50% reduction in the number of work accidents per month is observed as a result of the implementation of Lean tools. The influence of the selected Lean tools on increasing both productivity and safety is clear, and our results prove the selection of tools to be largely adequate.Repositório Científico do Instituto Politécnico do PortoSá, José CarlosSoares, LeonardoDinis-Carvalho, JoséSilva, FranciscoSantos, Gilberto2024-01-29T12:39:22Z2023-10-052023-10-05T00:00:00Zinfo:eu-repo/semantics/publishedVersioninfo:eu-repo/semantics/articleapplication/pdfhttp://hdl.handle.net/10400.22/24783enghttps://doi.org/10.3390/ safety9040070info:eu-repo/semantics/openAccessreponame:Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos)instname:Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informaçãoinstacron:RCAAP2024-01-31T01:51:11Zoai:recipp.ipp.pt:10400.22/24783Portal AgregadorONGhttps://www.rcaap.pt/oai/openaireopendoar:71602024-03-20T01:59:08.983961Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) - Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informaçãofalse
dc.title.none.fl_str_mv Assessment of the Impact of Lean Tools on the Safety of the Shoemaking Industry
title Assessment of the Impact of Lean Tools on the Safety of the Shoemaking Industry
spellingShingle Assessment of the Impact of Lean Tools on the Safety of the Shoemaking Industry
Sá, José Carlos
Gemba walk
Lean safety
orthopedic footwear
total productive maintenance
value stream mapping
overall equipment effectiveness
Yokoten
title_short Assessment of the Impact of Lean Tools on the Safety of the Shoemaking Industry
title_full Assessment of the Impact of Lean Tools on the Safety of the Shoemaking Industry
title_fullStr Assessment of the Impact of Lean Tools on the Safety of the Shoemaking Industry
title_full_unstemmed Assessment of the Impact of Lean Tools on the Safety of the Shoemaking Industry
title_sort Assessment of the Impact of Lean Tools on the Safety of the Shoemaking Industry
author Sá, José Carlos
author_facet Sá, José Carlos
Soares, Leonardo
Dinis-Carvalho, José
Silva, Francisco
Santos, Gilberto
author_role author
author2 Soares, Leonardo
Dinis-Carvalho, José
Silva, Francisco
Santos, Gilberto
author2_role author
author
author
author
dc.contributor.none.fl_str_mv Repositório Científico do Instituto Politécnico do Porto
dc.contributor.author.fl_str_mv Sá, José Carlos
Soares, Leonardo
Dinis-Carvalho, José
Silva, Francisco
Santos, Gilberto
dc.subject.por.fl_str_mv Gemba walk
Lean safety
orthopedic footwear
total productive maintenance
value stream mapping
overall equipment effectiveness
Yokoten
topic Gemba walk
Lean safety
orthopedic footwear
total productive maintenance
value stream mapping
overall equipment effectiveness
Yokoten
description Both the Lean philosophy and occupational safety and health have been widely studied, although this has usually been carried out independently. However, the correlation between Lean and occupational safety and health in the industrial context is still underexplored. Indeed, Lean tools can be applied to ensure the best safety environment for workers in each kind of manufacturing process, and this deserves to be studied. The study described here aims to understand the influence of each of a set of four Lean tools used in an industrial context with a strong manual labor component, seeking to determine the influence of each of these Lean tools on the increase in safety obtained through their application. For this purpose, four Lean tools that are quite commonly applied are selected, taking into account previously presented work that pointed to the positive influence of the application of each of these tools on worker safety: total productive maintenance system, Gemba walk, visual management and Yokoten. This study aims to apply these Lean tools and to analyze their impact on productivity, and then, on the safety of a company selected as a target in order to validate the concept. For this purpose, a new tool is created. In the first instance, the tool analyzes the current state of the productive process and the safety level through the study of the risk levels detected in the plant. In terms of productivity results, a reduction between 7% and 12% in cycle time is achieved in four areas of the plant. The feedback from employees showed increased satisfaction with the processes’ simplification. To conclude, a 50% reduction in the number of work accidents per month is observed as a result of the implementation of Lean tools. The influence of the selected Lean tools on increasing both productivity and safety is clear, and our results prove the selection of tools to be largely adequate.
publishDate 2023
dc.date.none.fl_str_mv 2023-10-05
2023-10-05T00:00:00Z
2024-01-29T12:39:22Z
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dc.relation.none.fl_str_mv https://doi.org/10.3390/ safety9040070
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