DOI: 10.18503/1995-2732-2025-23-1-110-118
Abstract
One of the priority directions of enterprise development in the context of increasing competition is the introduction of a lean manufacturing system. Significant support in this area is provided by national programs that enable the transfer of competencies and best practices for improving labor productivity. Replication of large companies experience without taking into account the level of development of enterprises leads to a violation of the general knowledge system, the chaotic nature of the implemented tools and, as a result, a decrease in the interest of manufacturers in the development of the system after the completion of the program. According to statistics, no more than 15% of the enterprises for the production of metal structures participating in the program continue to improve the lean manufacturing system. To solve the described problem, the development of a scientific and methodological approach to planning a lean manufacturing system, taking into account the level of development of the enterprise, is of particular relevance. The paper analyzes the theory of profound knowledge by E. Deming, a classical and flexible management model, and proposes a new hybrid management model. The model developed by the authors includes a two-circuit control cycle (PDSA and PDCA cycles) and a three-circuit learning cycle. The core of the model is the foundations of the theory of profound knowledge by E. Deming. The toolkit developed by the authors allows to implement the model: ranking organizations by level of development using the color code of F. Laloux's organizational models; stratification of lean manufacturing methods taking into account the main components of E. Deming's theory: understanding the system, understanding the theory of variability, understanding the basics of the theory of cognition and knowledge of psychology; assessment of the priority of lean manufacturing methods, taking into account the strategic goals of the organization. The approbation of the hybrid model and the developed toolkit at a metal structure manufacturing enterprise in the Tula region allowed: to link the goals, the level of development of the enterprise and the range of possible combinations of lean manufacturing methods; to identify the main reasons for the decrease in employee interest in promoting the concept of lean manufacturing; to substantiate and supplement the range of lean manufacturing methods mastered during the period of participation in the national project. According to preliminary forecasts, the implementation of the proposed model and toolkit will increase production efficiency by up to 20% and will allow achieving a twofold increase in efficiency in two years.
Keywords
lean manufacturing, E. Deming's theory of profound knowledge, lean manufacturing methods, hybrid management model
For citation
Gorelikov A.A., Plakhotnikova E.V. Hybrid Management Model for System Implementation Processes of Lean Manufacturing at Metal Structures Enterprises. Vestnik Magnitogorskogo Gosudarstvennogo Tekhnicheskogo Universiteta im. G.I. Nosova [Vestnik of Nosov Magnitogorsk State Technical University]. 2025, vol. 23, no. 1, pp. 110-118. https://doi.org/10.18503/1995-2732-2025-23-1-110-118
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