In a highly competitive and changing industrial environment, an organizational system that remains permanently aligned with the market is becoming a competitiveness factor. The literature shows that the empowerment of people is a key factor for maintaining and improving such a system. Consequently, industrial organizations face the challenge of building effective production systems that integrate the development of people, thus improving their capacities and skills for solving complex problems while respecting their needs and aspirations as individuals. This challenge is particularly relevant when intensive handwork is needed and, consequently, high pressure on labor (and space) productivity constitutes the main cost drivers. This paper proposes a method to design lean factories, thus fostering high productivity rates and respect-for-human.
We develop here a holistic model for a system as an integrated set of Principles, Tools and Methods in constant interaction with people. Afterwards, the model is specified for Lean Production Systems. We propose a specific human-centered method (Person-Based Design) to guide an effective lean factory design in a real industrial setting, and then we present some results from its implementation.
The outcomes of this research provide a coherent mindset for managers facing an organizational change, and our structured method allows for the design of effective lean factories, which are particularly useful when space and/or labor productivity constitute the main factors of a firm’s competitiveness
