Integration of lean manufacturing system with novel intuitive fuzzy syncretic lean frame work to improve the overall equipment effectiveness.

The article focuses on the development and implementation of a novel intuitive fuzzy syncretic lean framework that integrates lean manufacturing principles with intelligent systems, specifically fuzzy logic and embedded smart sensors, to enhance production efficiency and quality in manufacturing firms. The framework operates in three phases—design, manufacturing, and inspection—employing fuzzy time-based forecasting (using the lean tool Takt time), predictive maintenance through sensor data for continuous flow, and real-time monitoring for defect prevention (Poka-yoke). Simulation results demonstrate significant improvements over existing methods, including faster sensor response, higher fault prediction accuracy, and enhanced overall equipment effectiveness, leading to reduced waste, timely production, and improved customer satisfaction. The study acknowledges challenges in adopting fuzzy logic within traditional lean environments but highlights the framework's potential to optimize resource use and sustainability in dynamic industrial settings.