Lean Manufacturing Implementation Research Articles

Lean Manufacturing en la producción de alimentos: Revisión sistemática, análisis bibliométrico y propuesta de aplicación

In a changing environment, efficiency and adaptability are essential to improve business competitiveness. The present study analyzed the application of Lean Manufacturing in food production through a review of the scientific literature based in Scopus, using the PRISMA methodology and the Vosviewer and Bibliometrix software. From the bibliometric analysis, there is evidence of an increase in research on Lean Manufacturing in food companies since 2019, with an annual growth rate of 5.96%. Brazil and Peru stand out for their high scientific production, while Brazil and Belgium stand out in terms of citations. In addition, outstanding scientific collaboration between authors from South America and Asia is observed. Three relevant clusters were identified: principles, implementation tools and practical applications of Lean Manufacturing. The thematic mapping highlighted the concepts Cost Reduction, Process Monitoring, Six Sigma and Value Stream Mapping as the most prominent topics underlining the interest and applications in the scientific literature. The implementation of Lean Manufacturing in seven steps is proposed, facilitating the use of agile tools for process optimization and waste reduction in food companies. Lean Manufacturing contributes to improve the flow of products in the supply chain and to the sustainability of small and medium enterprises. Future research should focus on adapting Lean Manufacturing to various contexts and business models in the agri-food sector.

Lean Manufacturing Implementation in Developing Countries:Evidence from Jordanian Industrial Companies

In today's fiercely competitive landscape, industries are increasingly embracing lean manufacturing strategies for survival. However, the adoption of lean principles in Jordanian manufacturing sectors remains relatively new. This study aims to evaluate the current state of lean adoption in Jordanian industries, focusing on its techniques, motivations, and challenges. Employing a quantitative methodology, surveys targeted Production, Operation, and Quality Managers in Jordanian organizations. Out of 300 distributed questionnaires, 176 valid responses were received, representing a response rate of 58.7%. The findings indicate a relatively low adoption of lean practices in Jordanian industries, though firms that have implemented lean report significant benefits, particularly in quality enhancement and cost reduction. Key challenges include inadequate training, a scarcity of experts, and complexities in small batch production. While the study's sample size is limited, caution is warranted in interpreting the results. Further empirical research is needed to quantify the performance benefits of lean adoption. This study sheds light on lean adoption in Jordanian manufacturing, informing knowledge development and guiding future efforts to promote lean practices in the industrial landscape.

Implementation of Lean Manufacturing with VSM method for Increase TestingProcess Efficiency Laboratory Drug Antacid

Implementation of Lean Manufacturing with VSM method for Increase TestingProcess Efficiency Laboratory Drug Antacid

Study of SME employees’ awareness level on lean manufacturing and ergonomics implementation in Malaysian and Indonesian production environments

SMEs are small to medium-sized businesses with relatively fewer workers and lower revenues than large companies. However, SMEs also contribute to the local economic growth of a region, so the smooth production process needs to be considered to increase productivity. Applying lean manufacturing (LM) and Ergonomics concepts in the production process is critical because it can overcome smooth production and maintain the health and safety of SMEs workers. LM focuses on minimizing waste, while ergonomics focuses on humans as a source of energy in the smooth running of production activities. So, this study aims to measure the level of understanding of Malaysian and Indonesian SMEs workers on applying LM and Ergonomics concepts on the production floor and determine the effect of these two concepts using the SPSS and SmartPLS4 applications. SPSS serves to measure the validity, reliability and mean for the category of workers' understanding of LM and Ergonomics. SmartPLS4 helps us understand the influence of the two concepts. Based on the calculation of the mean for each variable of LM and ergonomics, it is found that Malaysian workers understand enough compared to Indonesian SMEs workers. As for the effect, Ergonomics has a significant influence on LM.

Application of Sensitivity Analysis for Multiple Attribute Decision Making in Lean Production System

Lean production is a dynamic process that is governed by a set of decision-making principles. The concept of MCDM has been widely used in lean production systems. In this paper, the methodology and approach of MADM, particularly focusing on Multi-Attribute Decision Making, encompass several key steps and considerations. To assess the degree of lean manufacturing implementation, a questionnaire was developed based on scholarly literature. The questionnaire consisted of 52 questions that assessed the implementation of four strategies: JIT, TPM, 5S Kaizen, and VSM. The study employed a three-stage elimination strategy, consisting of an elimination search and a TOPSIS-based ranking of lesions. Total Productivity Management was found to be the most effective and widely adopted approach among the 18 companies surveyed. TPM was the most widely adopted and effective waste reduction technique among the companies. The MADM ideology has significant future potential in various domains, including healthcare, supply chain management, energy and environmental management, financial sector, e-commerce, and marketing. This study provides insight into the practical application of waste reduction techniques by various industries and their potential benefits for a nascent company seeking to adopt such practices. These objectives aim to advance understanding, methodologies, and applications of MADM, particularly within lean production systems, while addressing challenges and leveraging advancements in technology for improved decision-making and performance optimization.

La importancia de la gestión de recursos humanos para la manufactura esbelta

Among the barriers to the successful implementation of lean manufacturing, the literature highlights human resource management. This study had two objectives: to analyze the influence of perceived organizational support on lean manufacturing practices and to establish whether gender is a factor associated with differences in the model. The research is quantitative, non-probabilistic, and cross-sectional, and the analysis techniques are structural equation modeling and multi-group analysis. It was identified that perceived organizational support was a trigger for commitment and participation. Together, these variables influence the use of lean manufacturing practices. Likewise, there are no differences in the model associated with gender. It is concluded that human resources determine the success of lean manufacturing.

A FRAMEWORK FOR LEAN MANUFACTURING IMPLEMENTATION IN THE TEXTILE INDUSTRY: A RESEARCH STUDY

This study investigates the implementation of lean manufacturing in the textile industry, focusing on its potential to enhance efficiency, reduce waste, and improve product quality. Lean manufacturing principles, including Just-In-Time (JIT) production, Kanban systems, value stream mapping, 5S workplace organization, and continuous improvement (Kaizen), have been widely recognized for their effectiveness in various manufacturing sectors. However, their application in the textile industry remains underexplored. Through a systematic literature review of 60 review papers and empirical analysis involving case studies, interviews, and surveys with industry experts, managers, and workers, this research identifies the significant benefits of lean practices in textile manufacturing. The findings reveal substantial efficiency gains, waste reduction, and quality improvements among companies adopting lean principles. Nevertheless, the study also highlights several industry-specific challenges, such as high variability in raw materials, complex production processes, and market pressures from fast fashion. These challenges necessitate tailored approaches and effective change management strategies for successful lean integration. Additionally, the research emphasizes the need for investment in advanced technologies and flexible manufacturing systems to enhance responsiveness to market changes. The study concludes that despite the challenges, lean manufacturing offers valuable strategies for textile companies aiming to improve their competitiveness and sustainability in the global market. This research contributes to the growing body of knowledge on lean manufacturing and provides practical insights for textile manufacturers seeking to adopt and optimize lean practices.

The Implementation of Lean Manufacturing on Zero Waste Technologies in the Food Processing Industry: Insights from Food Processing Companies in Kosovo and North Macedonia

This study aims to investigate the impact of lean manufacturing (LM) practices in the food processing (FP) industries of Kosovo and North Macedonia. It focuses on examining the effects of LM practices on operational performance metrics and evaluating the challenges and opportunities in integrating lean principles with zero waste (ZW) technologies and sustainability objectives. A qualitative multiple case study approach was used to examine nine case studies from companies in Kosovo and North Macedonia, with four companies from Kosovo and five from North Macedonia. Semi-structured interviews, guided by themes derived from a comprehensive literature review, facilitated in-depth discussions on lean practices and their influence on operational metrics and ZW technologies. For analyzing the qualitative data, a thematic analysis approach was employed, involving a multi-step coding process that ensured a comprehensive exploration and interpretation of the data. The thematic analysis uncovered that LM practices, such as Just-In-Time (JIT), Total Productive/Preventive Maintenance (TPM), Statistical Process Control (SPC), and employee involvement, considerably improve efficiency, quality, and responsiveness. The results demonstrate a close relationship between LM practices and sustainability goals, especially in waste reduction and resource optimization. Identified challenges include organizational resistance to change and resource constraints, while opportunities for improvement were noted in employee involvement, supplier engagement, and continuous improvement initiatives. This study underscores the potential of LM methodologies to boost operational performance, foster sustainability, and tackle specific challenges within the industry, offering key insights for enhancing sustainable food production in both Kosovo and North Macedonia.

ОЩАДЛИВЕ ВИРОБНИЦТВО: ІННОВАЦІЇ УПРАВЛІННЯ ПРОМИСЛОВИМ ПІДПРИЄМСТВОМ

The main problem is that the implementation of lean production requires not only technical changes, but also significant transformations in the organizational culture of the enterprise. Many Kazakhstani industrial enterprises face difficulties in the integration of lean principles due to the low level of awareness of management and personnel, insufficient training of personnel, as well as resistance to change, which is characteristic of many organizations. The purpose of the article is to research innovative approaches to the management of industrial enterprises by implementing the principles of lean production, as well as to develop a methodology that would facilitate the effective application of these principles in practice. The object of the study is the management processes of industrial enterprises in the context of the implementation of the principles of lean production. The methodological basis of the research was the logical methods of information processing, statistical analysis, comparison. The main hypothesis of the study is that innovations in the management of industrial enterprises, based on the principles of lean production, ensure the effective functioning of the enterprise in the long term due to the integration of the latest management practices that take into account the specifics of the domestic market and available resources. Presenting main material. The study covers the study of existing management practices, personnel training methods, and organizational culture transformation necessary for the successful implementation of lean manufacturing. Lean manufacturing is a modern concept of production process management aimed at reducing costs, improving product quality, and satisfying consumer needs. This approach, which was developed in Japan, in particular at the enterprises of the Toyota company, is now widely used all over the world, including Ukrainian industrial enterprises. Implementation of the principles of lean production requires not only technical changes, but also significant transformations in the organizational culture of enterprises, which is a complex and multi-stage process. Originality and practical significance of the research. In practice, the successful implementation of lean manufacturing requires a comprehensive approach that includes both technical and organizational measures. One of the key aspects is the adaptation of the best global practices to the specifics of a particular enterprise. For example, heavy industry may require longer staff training and a more thorough approach to change planning. Conclusions. The implementation of lean production is a strategic step that allows to increase the competitiveness of the enterprise, to ensure its sustainable development and successful functioning in the conditions of the modern economy.

Overviewing Challenges and Solutions in Lean Manufacturing Implementation for Domestic Enterprises

Companies keep focus on enhancing the quality, efficiency, and customer satisfaction of their products and services while at the same time increasing their profits. Lean Manufacturing emerges as a potent strategy to address these imperatives via identifying and eliminating losses. Hence, it leads to optimized production processes and enhances overall performance of enterprises. This study presents an overview and analysis of lean manufacturing principles, implementation strategies, challenges, and economic benefits for Ukrainian enterprises. The main hypostatize of the paper was to investigate whether the Lean manufacturing approach is associated with different scope of businesses and whether it brings efficient outcomes for all of them. Based on conducted structured literature review the study highlights the versatility of lean methodologies across various industries and administrative processes. Employing scientific methods like comparative analysis and theoretical generalization, the research offers insights into the outcomes of lean implementations, including cost savings, productivity enhancements, and improved product quality for business organizations. The main outcomes of study underscore the critical role of strong leadership commitment and organizational culture in driving successful lean transformations. Through overviewing case studies and practical insights, the article illustrates real-world applications of lean manufacturing principles from different industries, exemplified by organizations AeroStar, Nova Poshta and Boeing. The paper is theoretical. However, the study advocates the practical importance of adoption of lean principles to achieve operational excellence for companies regardless of their scope of operating activities. Also, it offers suggestions for future research to explore emerging technologies' impact and cross-cultural comparisons in lean manufacturing practices.

Implementation of lean manufacturing in a pharmaceutical distribution center: a case study

The present work aims to provide a brief case study of a distribution center of a major Brazilian pharmaceutical retail company. Initially, a quick literature review is presented regarding the fundamental concepts of Logistics, as well as its primary activities according to the most traditional literature, the concept of a distribution center, and the important characteristics for its proper functioning, and finally, the delimitation of the lean philosophy, elucidating key points to be used in its implementation. The study showed that, within a context of continuous improvements, lean practices implemented in production, such as VSM, are a powerful tool for diagnosing and repairing deviations. Thus, it is understood that the lean logistics philosophy is indeed key to the proper functioning of companies in general, especially for large distribution centers, whose merchandise flow depends on robust logistics at the end of the production chain.

Financial Management Strategies for Implementing Lean Manufacturing in the Footwear Industry

The concept of lean manufacturing, initially developed to maximize resource utilization by minimizing waste, has evolved to address the needs of a rapidly changing and competitive business environment. Footwear industries face significant challenges and complexities that require a systematic and continuous response to maintain and enhance product value. Implementing lean manufacturing practices has become essential for these organizations to sustain and thrive in such a dynamic landscape. However, successful implementation is not solely dependent on operational adjustments but also on strategic financial management. This research examines the financial management strategies necessary for the effective implementation of lean manufacturing in the footwear industry. It emphasizes the importance of integrating financial planning with lean principles to ensure comprehensive and sustainable improvements. Key lean elements such as Value Stream Mapping (VSM), Cellular Manufacturing (CM), U-line systems, Line Balancing, Inventory Control, Single Minute Exchange of Dies (SMED), Pull Systems, Kanban, and Production Levelling are explored in detail. The study demonstrates how a focused approach to financial management can support these lean elements, enabling footwear companies to optimize resource allocation, reduce costs, and improve efficiency. By aligning financial strategies with lean manufacturing goals, organizations can achieve significant economic and operational benefits. This includes better cash flow management, investment in continuous improvement initiatives, and a robust framework for measuring the financial impact of lean practices. Through a comprehensive analysis of these financial strategies, the research provides valuable insights for footwear companies aiming to implement lean manufacturing successfully. It highlights the need for an integrated approach that combines financial acumen with lean methodologies to drive value creation, enhance competitiveness, and ensure long-term sustainability in the industry.

The pathways to lean manufacturing for circular economy: Implications for sustainable development goals

Purpose This study aims to address the critical challenge of implementing lean manufacturing (LM) in emerging economies, where sustainability complexities on the production floor hinder production efficiency and the transition towards a circular economy (CE). Addressing a gap in existing research, the paper introduces a path analysis model to systematically identify, prioritize and overcome LM implementation barriers, aiming to enhance performance through strategic removal. Design/methodology/approach The authors used a mixed-method approach, combining empirical survey data with literature reviews to pinpoint key LM barriers. Using the grey-based Decision-Making Trial and Evaluation Laboratory (DEMATEL) along with the Network Knowledge (NK) method, they mapped causal relationships and barrier intensities. This formed the basis for developing a path simulation algorithm, integrating heuristic considerations for practical decision-making. Findings This analysis reveals that the primary barriers to LM adoption is the negative perception and inadequate understanding of lean tools and CE principles. The study provides a strategic framework for managers, offering new insights into barrier prioritization and overcoming strategies to facilitate successful LM adoption. Research limitations/implications This research provides a strategic pathway for overcoming LM implementation barriers, empowering managers in emerging economies to enhance sustainability and competitive advantage through LM and CE integration. It emphasizes the significance of structured barrier management in the manufacturing sector. Originality/value This research pioneers a systematic exploration of LM implementation barriers in the CE context, making a significant contribution to the literature. It identifies, evaluates barriers and proposes a practical model for overcoming them, enriching sustainable manufacturing practices in emerging markets.

Lean implementation barriers in the apparel industry in Bangladesh

PurposeIn the highly competitive business landscape, manufacturing firms need to adopt an effective manufacturing strategy to attain a successful world-class manufacturing status. Over the past few decades, the lean manufacturing (LM) approach has gained recognition as one of the foremost strategies for enhancing performance. However, the implementation of LM poses significant challenges due to several barriers. The purpose of this paper is to investigate the primary barriers to lean implementation within the apparel industry.Design/methodology/approachThis paper used an exploratory study approach, using a three-part structured questionnaire to assess the level of agreement on different lean barriers. The measurement of these barriers was conducted using a five-point Likert scale. Empirical data were collected from 177 apparel companies located in Bangladesh.FindingsThe findings of the research highlight that the primary obstacles to implementing LI include a lack of understanding of the lean manufacturing system (LMS), the manufacturing process, the company culture and resistance from employees.Research limitations/implicationsThis paper could potentially limit the generalizability of this research, as it exclusively examines a single manufacturing sector – the apparel industry.Practical implicationsThis paper will help practitioners in finding solutions to resolve discrepancies between current manufacturing practices and the LMS.Originality/valueThis paper fulfills an identified need to examine the extent of lean adoption within the apparel industry of Bangladesh.

Sustenance Strategies for Lean Manufacturing Implementation in Malaysian Manufacturing Industries

This study aims to investigate the relationship between sustaining factors and lean manufacturing implementation. This survey-based study was a cross-sectional study and the samples were drawn by using cluster sampling procedure from medium and large manufacturing companies based on the Federation of Manufacturers Malaysia (FMM) with the final number of 151 respondents. In total, four hypotheses were developed and tested statically using PLS-SEM through SmartPLS software. The result provided evidence that lean culture, lean leadership, and lean knowledge management have a positive relationship on lean manufacturing implementation. However, lean supplier management does not have a positive relationship on lean manufacturing implementation. The survey was responded by middle and top-level management from the discrete manufacturing industries. Although there is growing interest in empirical shreds of evidence in favor of sustaining lean, this study provides a comprehensive view of sustaining factors for lean manufacturing implementation. Hence, this study contributes to expanding the boundary of the existing literature and contributes to the body of knowledge while providing insights to practitioners in tailoring strategies to sustain lean manufacturing implementation and leverage their performance.

A Review of Literature on Lean Manufacturing Tools and Implementation Based on Case Studies

This research focuses on reviewing the Lean Manufacturing (LM) implementation which is widely applied in the manufacture company to overcome or reduce waste. The aim of this article is to find out more about the influence on the industry sector. This research was developed by collecting research from indexed databanks of Scopus, Science direct, ResearchGate, etc. This review study is significant to identify the application of lean manufacturing in dealing with waste through implementation into several case studies. A total of 24 articles were selected, taking into account criteria such as keywords, article titles and publications of international publishers, which were selected through a systematic process. This study found that the application of lean manufacturing is a method that brings many advantages that work by minimizing losses and waste, and the Value Stream Mapping method is more often used as part of several Lean Manufacturing techniques to identify and analyze the occurrence of waste while providing solutions that lead to improvement. process and cost reduction.

A Pilot Study on Lean Practice Implementation according to the Sizes and Ages of the Companies

The purpose of this paper is to address the accompanying lean manufacturing implementation barrier in terms of the sizes and ages of the companies. The 148 wood and furniture companies in Kuala Lumpur and Selangor were selected for the pilot research determinations. Smaller companies account for slightly more than 80% of newly founded and expanding wood and furniture industries, with 60% implementing lean practices. The practical implications indicate that the Malaysian furniture sector will have a promising future, with the number of medium-sized plants anticipated to increase in the upcoming years due to the increase in new and emerging businesses.

Lights on the Implementation of Lean Manufacturing in Moroccan Companies: Benefits, Barriers, Critical Success Factors (CSFs)

Lights on the Implementation of Lean Manufacturing in Moroccan Companies: Benefits, Barriers, Critical Success Factors (CSFs)

Lean manufacturing implementation in the food industry in Jordan

Lean manufacturing implementation in the food industry in Jordan

Implementation of Lean Manufacturing to Improve Production Efficiency: A Case Study of Electrical and Electronic Company in Malaysia

The manufacturing industry plays a crucial role in the economy development of a country includes Malaysia. Lean manufacturing is a production method that aims to minimize waste and optimize efficiency in the manufacturing process.By applying lean manufacturing,it enablesa company topursues continuous improvement and integration of labor with a clear focus on value adding activities and elimination of waste. However, this concept is still not widely being applied by all type of company or limited in certain aspects only. This study aims to implement lean concept into a medium sized electronic company in Malaysianamed as Company ABC, particularlyto improve the efficiency of the production line. Company ABC is expanding its production line, thus looking forward to implement 8 Waste and VSM to improve the Line Balancing Rate and improve the line productivityfrom 1500 units/ week to 3000 units / week.The clarifications lead to this study is to understand, how the Implementation of Lean Manufacturing can help to improve the production line efficiency, what are the factors that causes producibility issues during design development stage and what are the area of improvement of the manufacturing line of Model X that could be enhanced and applied in this particular project. The goal of this study is to assess the contributionof Lean six sigmain the companyto increase the process line productivity and maximize the efficiency of the production process. Amodelwas developedto simulate the efficiency improvement of the production line after application of Lean Manufacturing.