The convergence of lean management and additive manufacturing: Case of manufacturing industries

Lean practices in industry offered by lean management (LM) tools have revolutionized industrial production and operation. These tools allow for incorporation of pragmatic steps to reduce waste, improve flow of goods, and increase productivity in industrial settings. Novel manufacturing methods such as additive manufacturing (AM) promotes resource efficiency and cost efficiency which already is offered by LM. AM also aids in further waste minimization through light weighting, reduced scrap rate, shorter lead time, digital inventory, and energy-efficient parts. A preliminary review showed a lack of data on how LM and AM complement each other to-wards elimination of waste created. The aim of the study was to assess the prospect of the convergence of LM and AM to enhance resource efficiency and reduce waste, as well as the contribution to environmental, social, and economic aspects, i.e., the pillars of sustainability. The study methodology reviews literature of LM and AM including key concepts, tools, and technologies, and two industrial case studies of new product developments. The results show a distinctive stepwise approach by which organizations may identify and reduce waste in their operations by reduced cost, time, space, material usage, emissions, and digitalization. The novelty of the study is in addition to environmental benefits such as reduced emissions and reduced material waste, the convergence of LM and AM also contributes to economic and social sustainability, for example, through on-demand manufacturing which can provide better supply chain efficiencies, customized batch production, reduced lead time, etc., as well as reduced human fatigue and errors, workspace safety, ergonomic working, etc., respectively. The integration of LM and AM also reduces overproduction, process steps, and total cost of ownership through reduced need of physical spare parts. In this way, outdated or unmatched parts can be omitted, and replaced with on-demand manufactured AM spare parts.