Doctor of Philosophy, University of Akron, 2021, Engineering
Lean Management Systems (LMS) and Continuous Improvement (CI) program deployments are increasingly becoming an important strategy for many organizations for gaining competitive advantage. Such deployments promise success to organizations of any nature and size. Significant resources in the form of employee time, external consultants and training programs are spent on LMS/CI deployments by a vast number of companies every year. Yet despite the long history and evolution of CI methodology, ease of concepts and application, high amount of time and resources spent and furthermore proliferation of such deployments - the adoption and ultimately the success of such programs is highly variable. While many research papers and companies claim to have realized hundreds of millions in economic benefits from Lean deployments, just as many report to not even recover the cost of deployment.
Researchers conclude that a complete systems approach to successfully deploy Lean methodology for long-term sustained gains is not widely understood or practiced. For this reason, in this research I present the design work of a new way to approach Lean/CI deployment methodology utilizing first-principles.
The need for the new approach to deploying Lean/CI was engendered due to a mandate from the Senior Leadership Team (SLT) at the organization. The SLT desired a holistic approach that would align better to Company's Lean principles (first principles), show financial impact and bring about behavioral cultural change. This research presents the new approach - from First-Principles for the methodology, design criterion from SLT, to the design of the methodology, and then the application of the methodology to different businesses in the company. In essence, the research shows how any organization can build its own LMS utilizing first- principles to fit their own needs rather than copy pasting fragmented components offered by expensive consultants or snippets from literature – neither of w (open full item for complete abstract)
Committee: Shengyong Wang (Advisor); Asoke Dey (Committee Member); Xiaosheng Gao (Committee Member); Ping Yi (Committee Member); Chen Ling (Committee Member)
Subjects: Banking; Engineering; Industrial Engineering; Management; Mechanical Engineering; Systems Design; Systems Science