Awareness, implementation, effectiveness and future use of lean tools and techniques in Malaysia organisations: a survey

Abstract

This paper presented the results of awareness, implementation, the level of effectiveness, and potential future use of ten lean tools and techniques based on Malaysian organisational context. The ten lean tools and techniques being studied include 5S, Cellular Manufacturing (CM), Kaizen, Poka-Yoke, Standardised Work (SW), Value Stream Mapping (VSM), Jidoka, Kanban, Plan-Do-Check-Act (PDCA), and Total Productive Maintenance (TPM). This study was conducted due to the lack of existing studies on the current status of awareness, implementation, effectiveness, and future use of lean tools and techniques in Malaysia. An online survey was conducted for this study. The survey was distributed via email to 320 practitioners, managers, executives, consultants, and academicians who have been involved in the selection and/or implementation of lean tools and techniques. A total of 102 responses were returned from 320 industries resulting in 31.9% of valid response rate including responses after follow-up email. Data were analysed using the IBM SPSS software package. The findings indicated 5S as the most popular lean tool, followed by Standardised Work (SW), and Kaizen for Malaysian organisations based on the awareness, implementation, effectiveness, and future use of lean tools and techniques.