Using Process Modelling Tools to Support Lean Management Implementation
DOI:
https://doi.org/10.24425/mper.2025.157212Abstract
This paper aims to demonstrate that the implementation of Lean Management (LM) can benefit from prior process modelling and redesign using Business Process Model and Notation (BPMN). Single case study research was conducted, which allowed the detailed documentation of the operations of a wind blade manufacturer and the evaluation of the applicability of combining Business Process Management (BPM) and LM, which are two different process management approaches. BPMN allowed the identification of handoffs in the production process and the reassignment of tasks to eliminate waste. It provides a visual representation of process flows, facilitating a common understanding of the processes and providing a solid basis for discussing process improvements. As a result of the interventions, the cycle time of the target processes was reduced by up to around 30%. This work enriches the still scarce literature that crosses both fields. It also responds to the claims for more case study research on LM and studies with business collaboration.References
Aguilar-Savén, R.S. (2004). Business Process Modelling: Review and Framework. International Journal of Production Economics, 90 (2), 129–49. DOI: 10.1016/S0925-5273(03)00102-6
Badhotiya, G.K., Anand, G., Yogesh, M., and Gunjan, S. (2024). Lean Manufacturing in the Last Decade: Insights from Published Case Studies. Journal of Manufacturing Technology Management. DOI: 10.1108/JMTM-11-2021-0467
Basulo-Ribeiro, J., Amorim, M. and Teixeira, L. (2023). How to Accelerate Digital Transformation in Companies with Lean Philosophy? Contributions Based on a Practical Case. International Journal of Industrial Engineering and Management, 14 (2), 94–104. DOI: 10.24867/IJIEM-2023-2-326
Bernardino, S., and Ávila, L. (2025). Enhancing Production Planning and Control of Semi-Finished Products: A Case Study Combining Business Process Management and Lean Manufacturing. Gestao e Producao, 32, 1–19. DOI: 10.1590/1806-9649-2025v32e7624
Bortolotti, T., and Romano, P. (2012). Lean First, Then Automate: A Framework for Process Improvement in Pure Service Companies. A Case Study Production Planning and Control, 23 (7), 513–22. DOI: 10.1080/09537287.2011.640040
Calçado, R., Ávila, L., and Rosa, M.J. (2024). Combining Business Process Management and Lean Manufacturing to Improve Information and Documentation Flows: A Case Study. Business Process Management Journal. DOI: 10.1108/BPMJ-10-2023-0773
Dani, V.S., Dal Sasso Freitas, C.M., and Heloisa Thom, L. (2019). Ten Years of Visualization of Business Process Models: A Systematic Literature Review. Computer Standards and Interfaces, 66, 103347. DOI: 10.1016/j.csi.2019.04.006
Erasmus, J., Vanderfeesten, I., Traganos, K. and Grefen, P. (2020). Using Business Process Models for the Specification of Manufacturing Operations. Computers in Industry, 123, 103297. DOI: 10.1016/j.compind. 2020.103297
Ferreira, G.S., Assis, U., Rezende, S., Lucirton Costa, A. and de Dallavalle Pádua, S.I. (2018). The Promotion of BPM and Lean in the Health Sector: Main Results. Business Process Management Journal, 24 (2), 400– 424. DOI: 10.1108/BPMJ-06-2016-0115
Kitchenham, B., Pickard L., and Pfleeger S.L. (1995). Case Studies for Method and Tool Evaluation. IEEE Software, 12 (4), 52–62.
Klein, L.L., Schramm, M., Tonetto, L., Avila, V. and Moreira, R. (2021). Management of Lean Waste in a Public Higher Education Institution. Journal of Cleaner Production, 286, 125386. DOI: 10.1016/j.jclepro.2020.125386
Klun, M., and Trkman, P. (2018). Business Process Management – at the Crossroads. Business Process Management Journal, 24 (3), 786–813. DOI: 10.1108/BPMJ-11-2016-0226
Lukrafka, T.O., Souza Silva, D. and Echeveste, M. (2020). A Geographic Picture of Lean Adoption in the Public Sector: Cases, Approaches, and a Refreshed Agenda. European Management Journal, 38 (3), 506–17. DOI: 10.1016/j.emj.2020.02.004
Maldonado, M. U., Matheus, E.L., de Albuquerque Bernardes. T.C., and Rodrigues Vaz, C. (2020). Similarities and Differences between Business Process Management and Lean Management. Business Process Management Journal, 26 (7), 1807–31. DOI: 10.1108/BPMJ-09-2019-0368
Mamoojee-Khatib, H., Antony, J., Teeroovengadum, V., Garza-Reyes, J. A., Luz Tortorella, G., Foster, M. and Cudney, E. A. (2023). A Systematic Review of Lean Implementation Frameworks and Roadmaps: Lessons Learned and the Way Forward. TQM Journal. DOI: 10.1108/TQM-09-2023-0280
Maware, C., Okechukwu Okwu, M. and Adetunji, O. (2022). A Systematic Literature Review of Lean Manufacturing Implementation in Manufacturing-Based Sectors of the Developing and Developed Countries. International Journal of Lean Six Sigma, 13 (3), 521– 56. DOI: 10.1108/IJLSS-12-2020-0223
Mogotsi, K., and Saruchera, F. (2023). The Influence of Lean Thinking on Philanthropic Organisations’ Disaster Response Processes. Journal of Humanitarian Logistics and Supply Chain Management, 13 (1), 42– 60. DOI: 10.1108/JHLSCM-07-2022-0079
Naeemah, A.J., and Yew Wong, K. (2023). Selection Methods of Lean Management Tools: A Review. International Journal of Productivity and Performance Management, 72 (4), 1077–1110. DOI: 10.1108/IJPPM-04-2021-0198
Negrăo, L.L.L., Godinho Filho, M., and Marodin, G. (2017). Lean Practices and Their Effect on Performance: A Literature Review. Production Planning and Control, 28 (1), 33–56. DOI: 10.1080/09537287.2016.1231853
Nwabueze, U. (2012). Process Improvement: The Case of a Drugs Manufacturing Company. Business Process Management Journal, 18(4), 576–84. DOI: 10.1108/ 14637151211253738
Psomas, E. (2021). Future Research Methodologies of Lean Manufacturing: A Systematic Literature Review. International Journal of Lean Six Sigma, 12 (6), 1146-83. DOI: 10.1108/IJLSS-06-2020-0082
Ramadas, T., and Satish, K.P. (2021). Identification and Modeling of Process Barriers: Implementing Lean Manufacturing in Small-and Medium-Size Enterprises. International Journal of Lean Six Sigma, 12 (1), 61–77. DOI: 10.1108/IJLSS-09-2016-0044
Recker, J. (2010). Opportunities and Constraints: The Current Struggle with BPMN. Business Process Management Journal, 16 (1), 181–201. DOI: 10.1108/146 37151011018001
Sangwa, N.R., and Singh Sangwan, K. (2023). Prioritization and Ranking of Lean Practices: A Case Study. International Journal of Productivity and Performance Management, 72 (6), 1840–78. DOI: 10.1108/IJPPM04-2021-0214
Tortorella, G.L., Giuliano, A.M., Rogério, M., and Seidel, A. (2015). The Impact of Contextual Variables on Learning Organization in Firms That Are Implementing Lean: A Study in Southern Brazil. International Journal of Advanced Manufacturing Technology, 78 (9-12), 1879–92. DOI: 10.1007/s00170-015-6791-1
Voss, Ch., Tsikriktsis, N.and Frohlich, M. (2002). Case Research in Operations Management. International Journal of Operations & Production Management, 22 (2), 195–219. DOI: 10.1108/01443570210414329
Womack, J., and Jones, D.T. (2003). Lean Thinking: Banish Waste and Create Wealth in Your Corporation. 2nd ed. New York: Free Press.
Yin, R. (1994). Case Study Research : Design and Methods. 2nd ed. Thousand Oaks, CA: Sage Publications.
Zarour, K., Benmerzoug, D., Guermouche, N. and Drira, K. (2020). A Systematic Literature Review on BPMN Extensions. Business Process Management Journal, 26 (6), 1473–1503. DOI: 10.1108/BPMJ-01-2019-0040