Design of an Operations Management System for Continuous Improvement for Manufacturing Plants

Abstract

This thesis develops an integrated operational system for continuous improvement in manufacturing environments. The system is based on seven connected elements derived from Lean Manufacturing principles: Mission, Vision, and Values (MVV); Change Acceleration Process (CAP); Sociometry and Leadership Networks; Managing for Daily Improvements (MDI); Value Stream Mapping (VSM); Transfer Function Analysis; and Pulse Meetings. Together, these components form a structured approach that connects culture, leadership, process visibility, and analytical tools into one framework designed to improve operational performance. An extensive literature review was conducted using the Scopus and ScienceDirect databases, along with several specialized books on Lean Manufacturing, Value Stream Mapping, and Change Management. The first filter used the keyword “Lean Manufacturing,” generating 157 results, which were later refined using the seven elements mentioned above. A total of 53 relevant sources were selected for detailed analysis. The review showed that none of the identified studies combined all seven elements into a single operational system, confirming the originality and relevance of this research. Each chapter of the thesis explores one of these seven elements and explains how they work together as a continuous improvement system. The proposed framework demonstrates how Lean can be implemented not only as a set of tools, but as a complete organizational model that aligns purpose, leadership, and daily management. The system aims to strengthen performance in Safety, Quality, Delivery, Cost, and Engagement (SQDCE), while promoting learning, accountability, and sustainable growth. This work contributes a new perspective to Lean research by presenting a comprehensive and practical model for achieving continuous improvement in manufacturing operations. It serves as a guide for organizations seeking to integrate culture, leadership, and process management into a single system for operational excellence.