Lean implementation in Indian process industries – some empirical evidence

Abstract

Purpose – In the present era of intense competition, industries are adopting lean manufacturing for successful survival. The concept of lean manufacturing is new for Indian process industries. The purpose of this paper is to investigate the status of lean manufacturing in Indian process industries in terms of lean practices, reasons and challenges of implementing lean manufacturing. Design/methodology/approach – A survey was carried out to assess the level of lean implementation in Indian process industries. Statistical tests were conducted to assess the significant lean practices, reasons and challenges of implementing lean in Indian process industries. Findings – It is observed that the level of implementation of lean manufacturing in Indian process industries is still low. Results indicate that Indian process industries those who have implemented lean found lean to be very useful to reduce wastes and to increase quality. Major lean practices being implemented by Indian process industries are primarily those which are related to waste elimination or improvement in quality. Indian process industries found that important challenges to implement lean are to produce in small batches, to arrange for lean experts and to impart training to employees. Research limitations/implications – In the present study, the sample size is small and hence, the findings should be generalized cautiously. Although the study indicates that lean can be very useful if implemented in Indian process industries but further empirical studies are required to quantify performance improvements through adoption of lean. Originality/value – The paper explores status of lean adoption in Indian process industries. Considering the unique characteristics of process industries, the present research would be helpful for making strategies to implement lean in process industry setups.