Purpose The evidence suggests that, to sustain lean initiatives over time, it is essential to develop a lean culture among employees. However, when exploring "how" to develop this culture, the approaches often prove to be superficial and difficult to replicate across different organizations. Therefore, this study aims to propose a model based on short experimentation cycles for the development of lean culture.Design/methodology/approach Based on a literature review on the topic, a model incorporating active learning approaches and short experimentation cycles was proposed for the development of lean culture. This model was applied in six product development classes, during which data from 536 experimentation cycles were recorded. The results were then analyzed based on three proposed hypotheses.Findings The results provided evidence of the development of factors that characterize lean culture throughout the implementation of the model. Therefore, the proposed model provides a detailed framework for replication in other organization, thus filling the gap in the literature related to how to develop lean culture in people.Originality/value This study fills a research gap by presenting a structured and replicable model for developing lean culture. Moreover, it enables the evaluation of both people development and process improvement.

PurposeThis study aims to present a novel and flexible systematic method of Lean Maintenance designed to develop solutions and foster scientifically sustainable maintenance excellence. The method integrates the five Lean principles with short plan-do-check-act cycles promoted by the Toyota Kata approach to establish sequential target conditions. This systematic method highlights the active involvement of maintenance process executors in creating sustainable improvements.Design/methodology/approachThe proposed systematic method was applied through action research in a thermoplastics manufacturing company. The research team conducted the daily routine of Improvement Kata and Coaching Kata, and employees took part in the initiative. The results were assessed from the perspective of analyzing the improvement process with the team and the benefits for performance indicators.FindingsFrom the point of view of the company, the systematic method promoted problem-solving by strengthening the learning capacity developed through formalizing the maintenance sector's learning. There was an increase in the machines' Overall Equipment Effectiveness through improvements such as implementing Total Productive Maintenance, strengthening the 5S program and reducing the setup process. In addition, there was a change in how those involved in the process think by conducting small improvement cycles, which began to direct efforts and promote reflection on the results obtained with each action taken.Originality/valueWhile many companies face challenges in implementing Lean Maintenance due to the absence of a systematic and participatory approach, this study makes an original contribution by offering a replicable pathway that bridges theory and practice. The proposed method stands out for its flexibility, scalability and emphasis on the active involvement of shop-floor personnel, features that distinguish it from conventional top-down implementations. Furthermore, this work addresses a gap in the literature by formalizing a structured improvement routine in maintenance environments aligned with the Lean philosophy.

Nowadays, in the present dynamic industrial scenario characterized by shorter product life- cycles, customization, and uncertain demand, corporations should enhance their efficiency by reducing waste to remain competitive. This research addresses machine micro down-times, which embrace a significant waste source that negatively affects Overall Equipment Effectiveness (OEE). Although the literature presents some studies suggesting methods to mitigate micro downtimes, contemporary approaches focus on isolated strategies, lacking an integrated methodology. Accordingly, a research gap remains in developing a comprehensive framework that holistically improves OEE and systematically decreases micro downtimes within processes with bottlenecks. In this context, the objective of this study is twofold. First, we aim to introduce a Lean-based framework to reduce micro downtimes in manufacturing processes. Second, we present the results of applying this framework in a Brazilian tire company through a practical research approach. The results demonstrate a 1.6% reduction in machine micro downtimes, amounting to potential savings of USD 750,000 annually. Additionally, the implementation led to the improvement project's completion three weeks ahead of schedule, showcasing the framework's effectiveness. Although validated in tire manufacturing, the adaptable framework shows potential for broader use in other industries, offering a flexible approach to enhancing efficiency and competitiveness.

The objective of this paper is twofold. First, we aim to synthesize, evaluate, and discuss the main applications of Motion Capture Technologies (MOCAP) in industrial environments. Based on these results, we propose a theoretical framework that combines MOCAP technologies with the Value Stream Mapping (VSM) methodology from the Lean approach. A basic proof of concept is also presented. To accomplish the research objectives, a systematic literature review (SLR) was conducted. Data were collected in the Scopus database without time restriction. A total of 41 articles were selected to provide metadata that were analyzed and further used to propose the theoretical framework. Findings provide evidence that MOCAP technologies have the potential to revolutionize parameter and data acquisition in the manufacturing environment, as they are a human-centered type of sensing solution. Main application domains so far are ergonomic assessment, workplace design, and optimization of production systems. The proposed theoretical framework aims to initiate a debate on improving production processes in the Industry 4.0 and Industry 5.0 eras by combining MOCAP technologies and Lean concepts. The main limitations of this study are related to the defined query string and the databases, as some essential studies may have been left out. Furthermore, the proposed framework is theoretical, and only a proof of concept was developed, requiring further empirical evaluation in real industrial settings.

Industry 5.0 (I5.0) is based on the perspectives of sustainability, cybersecurity, and human centricity. This study focuses on Lean 5.0 and aims to evaluate the impact of adopting Lean 5.0 concepts from the perspective of the Toyota Kata (TK) approach within an assembly line through empirical research. The methodological approach followed the TK cycles, including diagnosing the current process, classifying activities (value-adding vs non-value-adding), proposing solutions based on Industry 5.0 principles, and analysing the outcomes. A Likert scale questionnaire was also applied to measure employee perceptions, further validating the experiment's findings. The results of this study demonstrated that combining TK with digitised work instructions improved assembly processes by reducing bottlenecks, enhancing training, and decreasing reliance on expert operators. The proposed application and related practices can be utilised by organisations to support the Lean 5.0 implementation of the TK concept. Copyright (c) 2025 The Authors.

Value is crucial to lean product development (LPD) and set-based design (SBD). Nevertheless, the literature needs to present more research on value definition and deployment to support exploring the design space. This scenario hinders the operationalization of lean initiatives in product development. This paper proposes a value deployment (VD) method for SBD, applying quality function deployment (QFD) matrices. We undertook a research action on the design of a TRL-6 magnetic air conditioner. As a result, we aligned teams and development efforts toward value, building clarity and cohesion about the contribution of subsystems to product performance. Furthermore, VD enabled the integration of manufacturing in decision-making. Our work paves the way for SBD in terms of practical relevance for industrial and systems engineering, assisting managers in adopting LPD and aligning integrated product teams toward value.

Manufacturing companies aim to increase their performance, efficiency, and competitiveness. In this sense, they emphasize the importance of controlling operational performance to make assertive decisions. Improving information flows is especially demanding in complex product environments. In this context, Value Stream Mapping (VSM) is a lean-based method used to maximize productivity by eliminating non-value-added activities. With the advent of Industry 4.0, this approach has undergone some modifications. VSM allows the virtualization of the company and can turn its physical processes into digital ones. Therefore, the objective of this paper is to review the practical applications of the VSM methodology in the context of I4.0 and propose a conceptual framework for this thematic. We used the PRISMA methodology (Preferred Reporting Items for Systematic Reviews and Meta-Analyzes) to conduct a systematic literature review about the thematic. As result, we provide a final portfolio of 37 records that were analyzed according to the research questions and a conceptual framework whose elements emerged from the literature review. This research contributes to the compose the academic production's overview of this thematic and opens a new horizon for future research work.

O objetivo deste trabalho é identificar se as rotinas de Toyota kata, utilizadas principalmente na Toyota, possuem relação conceitual com a aprendizagem organizacional, e são capazes de promove-la. Para chegar ao objetivo, desenvolveu-se uma revisão bibliométrica, somada a uma revisão narrativa, a fim de identificar estudos que corroborem com este trabalho, além identificar e demonstrar as relações que existem entre os temas abordados. Como resultados, pode-se identificar que os temas possuem significativa relação, e que as rotinas de Kata de Melhoria e Kata de Coaching utilizadas pela Toyota além de promoverem a aprendizagem organizacional, fazem isso de forma contínua, incremental e disseminada pela organização de maneira sistemática. Embora se tenha identificado a relação entre os temas propostos, ainda existem poucos estudos que consigam comprovar de forma empírica, que as rotinas de Toyota kata fomentem a aprendizagem organizacional de forma abrangente, nos mais variados contextos de mercado. De forma prática, este estudo possui suas limitações principalmente quanto ao seu empirismo. Como este trabalho está mais voltado em se identificar uma relação teórica, a parte empírica fica comprometida. No entanto, a mesma serve de oportunidade para trabalhos futuros, principalmente para a comprovação dessa relação teórica. Este estudo contribui de forma significativa ao estado da arte quanto a identificação de uma relação até então não abordada pela literatura, trazendo aos olhos dos pesquisadores uma nova relação teórica capaz de promover a pesquisa de futuros estudos empíricos que comprovem essa teoria.

Lean is a successful method used to identify waste and improve production systems. In recent years, the Toyota Kata (TK) approach emerge on how Toyota can improve continuously its process. TK describes a pattern to make the improvement process a routine. It aims to centralize the decision making on people who actively participate in the production processes. Through action research, the objective of this study was to use the TK approach to identify and characterize sources of waste in an automatic pipe grinding machine of a production system with the active participation of shop floor workers. As a result, it was identified that the operator has 59

Abstract Self-assessment in higher education institutions is a topic of increasing interest for the academic community, researchers, the government, and society. This process allows us to map the reality of the institution, becoming the foundation for proposing improvement actions. Self-assessment offers the potential to manage changes if they are considered in decision-making; universities, however, have difficulty using self-assessment as an management instrument; the step-by-step of this process and the use of its results are not effectively presented in the literature. Thus, this study aims to analyze the guidelines for self-assessment methods in higher education institutions, considering their processes, results, and effectiveness. The analysis of previously proposed attributes help to present the potential for developing a better practice in this area. A systematic review of the literature was conducted in several databases, including the Brazilian Digital Library of Theses and Dissertations. A total of 119 documents, relevant to this research were found, in which 62 presented some guideline that considered planning and management for decision-making. These guidelines may be considered as a possible systematic approach for institutional self-assessment. Additionally, research gaps were identified, supporting the appointment of opportunities for researchers and managers within the scope of process management, work routine, and human resources.

Shared Mobility Services (SHMS) are business models (BMs) that act as sharing economy platforms commonly based on mobile applications. They are conceived in a complex landscape characterized by the presence of information and the widespread presence of smart devices. In this sense, decision-makers, system developers, maintainers, and providers try to understand the interrelationships within this framework in terms of policy evaluation and/or impact on its successful adoption, analysis of all aspects of SHMS that affect the environment such as understanding patterns, user behavior, and improving the quality of this BM. To do this, models are built to capture the complex dependencies and interactions of these variables to guide decision-making. In this context, System Dynamics (SD) emerges as a useful approach to manage and capture the complexity/causality relationships of SHMS variables. Based on this, it developed a literature review to verify which research has applied SD to explore SHMS, analyzing existing models, their methods, variables, and impacts, as well as directions for future research. From a practical point of view, it is hoped that this research can be used as a guideline for urban planners and SHMS providers.

Toyota Kata (TK) approach emerged to how Toyota can continuously improve its processes over time. Thus, several western companies started using this approach to improve their production processes. However, there is a lack of studies that present and summarize the main opportunities and challenges when implementing and using TK in practice. Based on this, we present the result of a Structured Bibliographic Research (SBR) and a conducted SWOT analysis (strengths, weaknesses, opportunities, and threats) of the TK in a manufacturing environment. As result, it was possible to analyze eighteen works that discussed the implementation of the TK in industries. Several common aspects of the success, as well as the main barrier, could be identified. In the SWOT analysis, we demonstrated the main strengths to achieve the benefits of implementing TK. The weaknesses and threats identified may challenge some organizations. We also present a first conceptual model that aims to help organizations that want to use the TK approach in conjunction with others management approaches to improve its processes. As an implication, this manuscript presents the important steps organizations have taken to improve its processes. This way opens a new perspective for managers to lead in process optimization.

O objetivo deste artigo é identificar, através de uma revisão sistemática da literatura, comportamentos e atributos de liderança que afetam a implementação enxuta na saúde, além de quais práticas Lean foram utilizadas para isso. Como as organizações de saúde são únicas em muitos aspectos, os resultados sugerem por meio das características encontradas, que os líderes devem adaptar seus comportamentos ao iniciar a jornada rumo à gestão enxuta a fim de possibilitar a mudança de cultura. As contribuições que esse estudo pode oferecer são as características e as práticas que líderes lean poderiam ter e utilizar para implementar lean healthcare e assim tornar a cultura das organizações enxutas, e dessa forma tornar a própria organização enxuta ao longo do tempo. Existe um gap na literatura a qual não aborda de forma clara e objetiva a conexão entre atributos ou características essenciais de Liderança Lean na área de saúde que os líderes precisam desenvolver para tornar a implementação de Lean sustentável, bem como, quais são as práticas utilizadas para tal.

The literature acknowledges the advantages of Set-Based Concurrent Engineering (SBCE), but there is a lack of models for its adoption and documented cases of its implementation, mostly on products with consolidated technology, which raises the possibility of expanding SBCE for highly innovative products. These projects often have extensive resource limitations, leading to computational tools and mathematical modelling as fundamental sources of information. This paper proposes a method for model-based Trade-off Curves (ToC) generation to support SBCE. We adopted it to develop a magnetic air conditioner. The use of model-based ToC enabled the narrowing of the design space and monitoring of the design parameters and performance metrics and enabled SBCE adoption in the design process. The main contributions of this research are presenting the state-of-the-art in ToC generation and application, proposing the model, and demonstrating SBCE in highly innovative projects, while its importance lies in the opportunity to further disseminate SBCE to different development environments.

Integrate and involve manufacturing during the product design phase brings benefits to the product development process (PDP). Although this is an old subject of studies, it continues to be a challenge in the practice of industries, and the new agile methodologies can be crucial to facilitate and reach the integration of manufacturing in PDP in an effective way. Thus, the present work proposes a method to integrate the manufacturing in the PDP, based on the practices of the Lean Startup approach. To do this, structured bibliography research was carried out, and based on the findings the method was proposed. The method is compound by two main stages. The first refers to project planning, using a visual management tool called deliverable roadmap, while the second refers to the development and evaluation of what was developed of the product. This second stage is based on the build-measure-learn cycle of the Lean Startup approach and is the heart of the method. The proposed method can fill some gaps in the traditional methods of product development, while works the two faces of integration (interaction and collaboration) between manufacturing and the project team, in a more effective and anticipated way. With the proposed method, working in short cycles is possible to reduce uncertainties during development and the need for rework, improving the development process as a whole, as well as propitiate to work with a focus on valuing and developing people.

Diversos estudos já abordaram o ciclo de retrabalho em dinâmica de sistemas no que tange o gerenciamento de projetos. No entanto, mesmo este servindo para a grande maioria dos casos, algumas especificidades derivam deste modelo, principalmente pelo contexto avaliado. Com base nisso, e diante da dificuldade de gerenciar projetos de inovação, com altos riscos devido ao grau de incertezas, e sofrendo com atraso em entregas e no projeto, este estudo visa identificar quais a variáveis que mais ou menos influenciam nos projetos de inovação do Instituto Senai de Inovação de Sistemas Embarcados. Para tal, foi feito uma revisão tradicional somada a um estudo bibliométrico a fim de embasar este trabalho, junto a um estudo empírico utilizando dinâmica de sistemas, que resultou na identificação das principais variáveis que afetam o sistema de gestão dos projetos do instituto em questão, além de verificar que o mesmo amplia o conhecimento sobre dinâmica de sistemas em projetos e introduz novas variáveis as quais ainda há pouca abordagem. Several studies have addressed the rework cycle in system dynamics with regard to project management. However, even though it can be used in most cases, some specificities derive from this model, mainly due to the evaluated context. Based on this, and facing the difficulty of managing innovation projects, with high risks due to the degree of uncertainties, and suffering with delays in deliveries and in the project, this study aims to identify which variables have more or less influence in the innovation projects of the Senai Institute for Innovation in Embedded Systems. To this end, a traditional review was done together with a bibliometric study in order to base this work, together with an empirical study using system dynamics, which resulted in the identification of the main variables that affect the project management system of the institute in question, besides verifying that it expands the knowledge about system dynamics in projects and introduces new variables which there is still little approach.

Maintenance 4.0 (M4.0) is described as an innovative and optimized maintenance strategy, integrating existing practices with technologies from Industry 4.0. These technologies have been impacting and transforming several production processes and also maintenance management. It is possible to extract increasingly accurate data about the assets through sensors and other technologies in real-time. However, companies still struggle during the Maintenance 4.0 implementation, becoming an open field for research. Based on this, we developed a consistent literature review, followed by a SWOT analysis (strengths, weaknesses, opportunities, and threats) of Maintenance 4.0 implementation. The synthesis of the results was divided into bibliometric, thematic, and SWOT analyses. The bibliometric analysis showed the continuous growth of the theme in recent years. In the content analysis, the perspectives were grouped into (i) conceptual, theoretical studies, (ii) empirical studies/applications. In the SWOT analysis, we demonstrated the main strengths to achieve the benefits of implementing Maintenance 4.0. The weaknesses and threats identified may challenge some organizations. The implications of this study are in the organization of a comprehensive body of knowledge on Maintenance 4.0. From a practical point of view, it is hoped that this research can be used as a guideline, providing decision support to maintenance managers.

There are several benefits reported in the literature regarding the Lean approach and Industry 4.0 integration. In general, the most significant justification for integrating these two concepts is that incorporating new technologies in a production system should only occur once the system is operating without waste and in an optimized way. Thus, implementing the Lean approach represents an excellent opportunity for organizations that want to use the technologies of Industry 4.0 (I4.0). Although Industry 4.0 brings new opportunities for digitalizing production systems, machines and equipment cannot suggest improvements independently. In this way, employees will continue to be an integral part of production systems. However, when analyzing the specialized literature, it was possible to observe that the discussion about workers’ participation to effectively implement the new technologies of I4.0 in the productive systems is incipient. Thus, this work presents a new framework developed called Systematic for Process Improvement Using Cyber-Physical Systems and Toyota Kata that use the Improvement Kata and Coaching Kata routines and the cadence of activities from the training of employees to the development of the Cyber-Physical System of the organization to implement the new technologies of Industry 4.0. The systematic was tested in a theoretical case study, and the results showed that it was possible to develop a Cyber-Physical System using SIMIO® software. Improvements could be developed and simulated in the digital environment with data from the actual process.