Reliability in lean systems

Purpose – The purpose of this paper is to propose a contemporary reliability model for lean systems through the development of an innovative lean system reliability model (LSRM). Design/methodology/approach – LSRM models the reliability of lean subsystems as a basis for determining the reliability of lean systems as a whole. Lean subsystems, in turn, consist of reliability measures for lean components. Once principal components analysis techniques are employed to determine critical subsystems, Monte Carlo simulations for lean components, subsystems, and the overall lean system are then compared with historical data to determine the adequacy of the LSRM model. If simulation results are accurate to within the researcher's objective of 2.5 per cent of historical data results, the LSRM model is determined to be a validated model. Findings – A literature search shows limited practical methodologies to assess the reliability of lean systems. Research limitations/implications – Reliability computations involve many tedious calculations and, hence, require reliability software. Originality/value – This paper defines lean system reliability, develops a conceptual model to assess the reliability of lean systems, demonstrates how to decompose a lean system into subsystems and components, and compares simulation results versus actual results to validate the LSRM model.