Modeling Lean Manufacturing Strategies in the Supply Chain of Natural Stone Industry: A Hybrid Simulation and Multi-Criteria Decision-Making Approach

Document Type : Research Paper

Authors

1 Ph.D. Candidate in Industrial Management, Faculty of Management and Accounting, Allameh Tabataba’i University, Tehran, Iran.

2 Associate Prof., Department of Industrial Management, Faculty of Management and Accounting, Allameh Tabataba’i University, Tehran, Iran.

10.22059/imj.2025.393711.1008241

Abstract

Objective: Reducing waste and improving productivity are crucial challenges in today’s competitive manufacturing landscape. Lean production tackles these issues by eliminating activities that do not add value, cutting costs, and enhancing quality. However, the success of lean implementation relies on selecting strategies that align with an organization’s operational context. This study evaluates four fundamental lean strategies under various production conditions: Work-in-Progress (WIP) Inventory Reduction, Batch Size Reduction, Setup Time Reduction, and Multi-skilled Workforces.
Methods: A hybrid methodology was utilized, integrating discrete-event simulation (DES) with multi-criteria decision-making (MCDM). Six scenarios were modeled, varying production capacity (low, medium, and high) and work shift schedules (one or two shifts). The Best-Worst Method (BWM) was employed to determine the weights of the evaluation criteria: total cost, available inventory, waiting time, and lead time. The VIKOR method was then used to rank the strategies for each scenario.
Results: The results indicate that total cost (weight = 0.54) is the most critical evaluation criterion, followed by available inventory (0.27), waiting time (0.11), and lead time (0.08). Both simulation and VIKOR analyses demonstrated a contextual pattern: reducing setup time was more effective than other strategies in low-capacity environments. In contrast, reducing batch size consistently ranked highest in medium and high-capacity environments, regardless of the shift schedule.
Conclusion: The findings highlight that lean strategies' effectiveness depends on the context. Reducing setup time is most beneficial for resource-limited systems, while reducing batch size offers greater advantages in high-output environments. The hybrid simulation-MCDM framework created in this study is a structured and objective tool for managers, allowing them to choose lean strategies aligned with their specific operational conditions. This, in turn, enhances supply chain performance and fosters long-term competitiveness.

Keywords

References

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Industrial Management Journal
Volume 17, Issue 3
2025
Pages 180-202

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