Recent Advances in Lean Techniques for Discrete Manufacturing Companies: A Comprehensive Review

Abstract

Background: Against the backdrop of the transformation and upgrading of the manufacturing industry, lean manufacturing has emerged as a systematic and advanced production paradigm that has deeply permeated the entire value chain of enterprises. Objective: However, there is a lack of systematic and effective lean technology paradigms in aspects such as lean practice processes and improving manufacturing process efficiency. Moreover, a comprehensive analysis of the current status and development strategies of lean technologies in discrete manufacturing enterprises has yet to be conducted to address issues such as the fragmentation of lean technology applications and the ambiguity of implementation strategies in discrete manufacturing enterprises. Methods: This paper conducts an extensive review of the literature on lean technologies and transformation methods in discrete manufacturing enterprises. A multi-stage data analysis approach (including data identification, screening, eligibility assessment, classification, and comprehensive analysis) is utilized to analyze 369 highly relevant documents. Results: The main contributions of this study are as follows: (1) A comprehensive review of existing lean manufacturing technologies and methods is provided, classifying, comparing, and summarizing the current status of lean technology and strategy applications, and delineating nine categories of lean technology application directions. (2) A “5P” theoretical framework (Philosophy, Process, People, Problem-solving, and Product) is proposed, redefining a lean technology framework that covers the value streams of discrete manufacturing. (3) Future application trends of lean technologies in discrete manufacturing are summarized and predicted, and an implementation strategy for lean technologies tailored to small and medium-sized discrete manufacturing enterprises, along with six lean technology development strategies, are proposed. The results indicate that many enterprises have derived diversified methods based on their own circumstances, which compensate for the deficiencies of the original lean models. Discussion and Conclusions: This paper organizes these methods to serve as a reference for future research on the lean technology system. The proposed strategies include formulating lean transformation strategies for discrete manufacturing enterprises, enhancing proactive lean capabilities, adapting to passive lean factors, and creating value for the enterprises’ reasonable lean needs from three levels: strategic philosophy, objective principles, and tool technologies. This research will play a guiding role in promoting the coordinated development of lean implementation and achieving high-quality development in discrete manufacturing enterprises.