Abstract
Purpose: Lean Manufacturing System has emerged as an important area of research in Indian context. The requirement of Lean Manufacturing has increased due to defects in products (semi finished and finished) and subsequent increase in cost. In this context, this study is an attempt to develop a structural model of the variables, important to implement Lean Manufacturing System in Indian automobile industry. Design/Methodology/Approach: Various variables of lean manufacturing system implementation have been identified from literature review and experts’ opinions. Contextual relationship among these identified variables has been set after carrying out brainstorming session. Further, classification of the variables has been carried out based upon the driving power and dependence. In addition to this, a structural model of variables to implement lean concept in Indian automobile industry has also been developed using Interpretive Structural Modeling (ISM) technique. Questionnaire based survey has also been conducted to rank these variables. Findings: Eighteen variables have been identified from the literature and subsequent discussions with experts. Out of which, nine variables have been identified as dependent and nine variables have been identified as driver. No variable has been identified as linkage variable and autonomous variable. From the model developed, ‘Relative cost benefits’ has been identified as top level dependent variable and top management commitment as bottom level most independent variable. Research limitations/Implications: The model so developed is a hypothetical model based upon experts’ opinions. The conclusions so drawn may be further modified to apply in real situation. Practical implication: Clear understanding of interactions among these variables will help organizations to prioritize and manage these variables more effectively and efficiently to draw advantage from lean manufacturing system implementation. Originality/value: Through this paper we contribute to identify the variables to implement lean manufacturing system in Indian automobile industry and prioritize them. The structured model developed will help to understand interdependence of the variables of lean manufacturing system implementation.
Highlights
Lean manufacturing is a conceptual framework recognized in many industrial companies since the early 1990s (Womack & Jones, 1994)
During the preliminary literature review, it has been observed that less research work is reported on lean manufacturing system implementation in Indian context; identification of variables relevant to Indian automobile industry need to be done; and dynamics of these variables needs to be examined
The various steps involved in the Interpretive Structural Modeling (ISM) methodology are as follows: Step 1: Variables affecting the system are listed; in our research work factors to implement lean manufacturing system in Indian automobile industry have been identified as variables
Summary
Lean manufacturing is a conceptual framework recognized in many industrial companies since the early 1990s (Womack & Jones, 1994). Lean manufacturing can be best explained as eliminating waste in a production process (Womak & Jones, 1996). Anything (process or product tangible and intangible) that does not add value to the end product is called waste (Henderson & Larco, 2003). Lean manufacturing seeks to produce a product that is exactly what the customer wants at right time, minimizing all non-value added activities in the production (Womack & Jones, 1994). When the time comes to begin the transformation to lean, management will need to get people together and making them aware what is going to happen, and what is expected (Henderson & Larco, 2003). Efficiency of manufacturing has been an objective in development of Toyota Production System (TPS) (Holweg, 2007)
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