Adoption Of Lean Manufacturing Research Articles

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.

Determinants of lean manufacturing adoption by Chinese manufacturers

Purpose This study aims to analyze the determinants influencing Chinese manufacturing companies in implementing lean manufacturing (LM). Design/methodology/approach The determinants to be explored in this study consist of technological, organizational and environmental (TOE) dimensions. A questionnaire survey was conducted on Chinese manufacturing companies, and 208 samples were analyzed. Findings The findings show that the relative advantage of LM and organizational support have significantly positive effects on Chinese manufacturing firms’ adoption of LM. The complexity of LM, quality of human resources, organizational readiness, customer pressure, international situation, governmental support and environmental uncertainty do not have significant effects. Originality/value This paper contributes to the literature by using the TOE model to explore the factors influencing LM adoption in the Chinese manufacturing industry.

Exploring lean manufacturing drivers for enhancing circular economy performance in the pharmaceutical industry: a Bayesian best–worst approach

PurposeThe imperative to conserve resources and minimize operational expenses has spurred a notable increase in the adoption of lean manufacturing within the context of the circular economy across diverse industries in recent years. However, a notable gap exists in the research landscape, particularly concerning the implementation of lean practices within the pharmaceutical industry to enhance circular economy performance. Addressing this void, this study endeavors to identify and prioritize the pivotal drivers influencing lean manufacturing within the pharmaceutical sector.FindingsThe outcome of this rigorous examination highlights that “Continuous Monitoring Process for Sustainable Lean Implementation,” “Management Involvement for Sustainable Implementation” and “Training and Education” emerge as the most consequential drivers. These factors are deemed crucial for augmenting circular economy performance, underscoring the significance of management engagement, training initiatives and a continuous monitoring process in fostering a closed-loop practice within the pharmaceutical industry.Research limitations/implicationsThe findings contribute valuable insights for decision-makers aiming to adopt lean practices within a circular economy framework. Specifically, by streamlining the process of developing a robust action plan tailored to the unique needs of the pharmaceutical sector, our study provides actionable guidance for enhancing overall sustainability in the manufacturing processes.Originality/valueThis study represents one of the initial efforts to systematically identify and assess the drivers to LM implementation within the pharmaceutical industry, contributing to the emerging body of knowledge in this area.

Assessing the barriers to lean manufacturing adoption in the furniture industry of Bangladesh: a fuzzy-DEMATEL study

Assessing the barriers to lean manufacturing adoption in the furniture industry of Bangladesh: a fuzzy-DEMATEL study

Examining the Adoption of Lean Manufacturing in Lima Companies: An Exploratory Study of University Theses

Purpose: The objective of this research was to know the results of the adoption of lean manufacturing in companies in Lima, which were reported in theses for university degrees. Theoretical framework: The adoption of lean manufacturing is challenging and complex and requires specialized process management due to the various barriers and drivers to adoption. Design/methodology/approach: The study was conducted using an exploratory and descriptive methodology that consisted of reviewing university theses related to lean manufacturing. Subsequently, companies were identified and contacted by telephone, applying questionnaires with direct questions about adoption results. Findings: The results were obtained from the review and comparison of university repositories, SUNAT (Superintendencia de administración tributaria) and telephone calls. Descriptive analyses were performed to evaluate the results, which provided insight into the application of the methodology. Research, Practical & Social implications: It is suggested for future research to explore the adoptions of lean manufacturing proposed in articles of indexed journals to learn about their experiences and adapt them to the national reality. Originality/value: The results indicate that most of the university theses reviewed only propose the adoption of lean manufacturing and have not been implemented due to the complexity and sustainability of the methodology.

The Implementation of Lean Manufacturing System in Production Process Theoretical Analysis and Empirical Investigations. An Empirical Study on the Manufacturing Companies in Poland

Purpose: The purpose of this paper is to investigate the implementation of Lean Manufacturing System (LMS) in the manufacturing companies of Poland. Design/methodology/approach: Using a survey questionnaire, data was collected against the most common lean practices and tools which formed the Lean House (LH) presented by Liker (2004), from 40 manufacturing companies acting in Poland. Lean practices and tools were clustered into five groups according to its position in the LH structure: The roof: the goal of lean manufacturing system, the lift pillar: Just-in-Time principle (JIT), the right pillar: Jidoka tool, the center: People who identify wastes and solve problems to insure continuous improvement, and the foundation: Lean Tools: 5S, Standardization, Visual Management and Production levelling. The responding companies were categorized according to their respective field of production and the company size (big, middle and small). 181 manufacturing companies acting in the manufacturing field of Poland were contacted, 40 companies participated and 3 of them were excluded due to lack of implementation. The results identified by statistical analysis to find out the Average and the Percentage of implementing each and all Lean Manufacturing practices and tools. Findings: The manufacturing companies in Poland have implemented various lean practices and tools to a certain extent. However, the results suggest that the adoption of lean manufacturing as a fully integrated, systematic, and cultural approach may not be highly developed enough. Hence, reaping the maximum benefits of the LMS in those companies may be doubted. Research limitations/implications: Since the sample size is not very large, the results need to be considered with caution as being limited to the participated companies. Practical implications: The paper gives an indication about the status of the implementation of LMS in the Polish manufacturing companies. It also includes a description for better understanding of Lean concept and practices through a specific literature review. Originality/value: The implementation of LMS was researched widely in different countries all over the world and some of them are EU countries. Despite that, there is a lack of similar studies in the manufacturing companies in the 10 countries which have joined the EU in the year 2014, and specifically in Poland. Moreover, this paper also illustrates a better understanding of the Lean concept through a literature review of selected recognized articles dealt with this concept.

Digitalization: a tool for the successful long-term adoption of lean manufacturing

Digitalization: a tool for the successful long-term adoption of lean manufacturing

Conceptual model for assessing the lean manufacturing implementation maturity level in machinery and equipment of small and medium-sized enterprises

The adoption of lean manufacturing (LM) in small and medium-sized enterprises (SMEs) is not as vigorous as in large organizations. This purpose of this study is to assess the maturity level of LM implementation in the machinery and equipment (ME) SMEs. The close-ended survey questionnaire method was adopted in three Malaysian manufacturing ME SMEs, and data was collected for the descriptive analysis. The findings showed that these case companies are generally at a low-to-moderate level in terms of LM understanding. Meanwhile, the extent of LM implementation and the success level is still moderate. The proposed LM conceptual model provides valuable perspectives and establishes a holistic understanding of the phenomena in LM maturity status for ME SMEs. The proper synchronization of LM understanding, implementation, and success are vital to building the strong LM maturity foundation for lean organizational transformation. It serves as useful guidance and strategic framework to other companies in dealing with the operational excellence challenges. The significance of this study will help ME SMEs to identify their current position and promote progress in the lean application journey. This will benefit the management team and lean practitioners in decision-making and enhance tactics to attain a higher level of success.

Interdependency analysis of lean manufacturing practices in case of Bulgarian SMEs: interpretive structural modelling and interpretive ranking modelling approach

PurposeThe paper aims to analyse the contextual relationship and dependency amongst enablers for lean manufacturing implementation in Bulgarian small and medium-sized enterprises (SMEs).Design/methodology/approachIn this study, the interpretive structural modelling (ISM) technique was used to develop a hierarchical structural model for enablers. Also, the interpretive ranking process (IRP) was used to analyse and rank enablers with reference to performance variables. For the ISM approach, a structural self- integration matrix was developed with the help of experts’ suggestions and opinions. Cross-impact matrix multiplication applied to classification (MICMAC) analysis was used to analyse the relationship amongst enablers. A total of nine experts were chosen for collecting the primary data in which seven experts belong to the industry and two experts were academicians. The dominant relationship amongst the enablers was analysed through IRP modelling.FindingsA total of 11 enablers were identified for the purpose of this study. The model shows that “leadership and commitment by management”, “human resource management”, “customer relation management”, “supplier relation management” and “information technology system” are the most significant enablers for lean implementation in Bulgarian SMEs as these are positioned at the bottom levels in ISM model. MICMAC analysis shows that five enablers fall in the independent factor, two enablers in linkage factor and four enablers in the dependant factor while there is no enabler in the autonomous factor. ISM and IRP models show that “continuous improvement” is an essential enabler for the successful implementation of lean in Bulgarian SMEs. This study also helps to explain the comparative analysis of ISM and IRP, which indicates that IRP is a more robust modelling approach than ISM, as it incorporates the relationship of enablers with performance variables.Research limitations/implicationsISM and IRP modelling approaches are based solely on expert opinions and responses. This limitation can be overcome with the help of empirical study.Practical implicationsThis study supports the professionals/experts to prioritise and manage enablers at strategic and tactical levels while implementing lean manufacturing practices in Bulgarian SMEs. The models developed in the study will be helpful for practitioners to understand and analyse the interdependence of enablers for lean manufacturing implementation.Originality/valueThis study helps to identify and prioritise enablers that affect lean manufacturing adoption using ISM and IRP approaches. Literature shows that numerous authors have used the ISM approach but the use of IRP approach is limited. The models were developed in the study, totally dependent on data collected from the experts to ensure their real-life validity.

Development of a lean manufacturing framework to enhance its adoption within manufacturing companies in developing economies

Abstract: The urgent need to reduce negative corporate environmental impacts while enhancing their financial strength and positive societal benefits is attracting company leaders to implement various quality improvement systems such as lean manufacturing, six sigma, sustainable manufacturing, and circular economy concepts, approaches and technologies. All of these approaches are valuable, with Lean Manufacturing (LM) among the leading systems, if implemented within an appropriate framework. In that context, the objective of the authors was to document the drivers for improving implementation of LM within manufacturing companies. Implementation of LM practices is already providing competitive advantages such as improvements in product quality, productivity, worker health and safety and customer satisfaction in developed countries but has not been widely implemented in companies in developing countries. To help to enhance implementation of LM in developing countries, the authors developed a framework for enhancing the adoption of lean manufacturing processes in such companies. The hybrid Fuzzy Analytical Hierarchy Process (FAHP)- Decision Making Trial and Evaluation Laboratory (DEMATEL) tools were used as the framework to identify and to quantify the interrelationships among the drivers for implementation of LM. This hybrid approach facilitated documentation of the relative importance and priority of the thirty-one lean manufacturing drivers. The results revealed that improved shop-floor management, quality management, and manufacturing strategy drivers were among the most critical drivers, which enhance LM adoption. These findings are beneficial for company leaders and researchers working to improve environmental, economic and societal health, especially within companies in developing countries.

The implementation of lean manufacturing in the furniture industry: A review and analysis on the motives, barriers, challenges, and the applications

Although research on the adoption of lean manufacturing in the furniture industry in emerging economies is slowly progressing, its implementation has been emphasized by researchers and practitioners. Research on this scope is therefore limited, particularly when compared to the vast amount of scholarly studies contributed to successful implementation of lean in the developed countries. To support the narrow body of knowledge on this under-researched scope, this paper presents the current shortfalls of implementing the lean manufacturing in terms of motives, barriers, challenges, and applications. To address these issues, a methodological approach was implemented in two tiers. Firstly, a comprehensive review of state-of-the-art literature on the issues was performed followed by an analytic approach using a survey on 148 companies in Malaysia to finalize the research. Upon validation of the analyses, the results revealed that most of the lean companies agreed that the reasons for lean implementation are to increase efficiency, to clean up and organize the workplace, and to increase utilization of space. Non-lean companies believe that issues related to knowledge are the reasons for not undertaking lean implementation. However, lean companies believe that the obstacles are more about employee-related issues including lack of labor resources, lack of implementation know-how, and employee resistance to change. Lean companies also face challenges in the form of technical knowledge, training, and financial resources during the early phase of lean implementation. In addition, only three applications – 5S, employee training, and quality control – were found to be useable in the Malaysian wood and furniture industry. These findings present a critical view of the current shortfalls of lean implementation in the wood and furniture industry throughout Malaysia and other emerging economies.

Estudo comparativo entre a Adidas e a Nike sob o enfoque do ambiente Lean: manufacturing e accounting

Este artigo trata dos conceitos de Lean Manufacturing ou Manufatura Enxuta e Lean Accounting ou Contabilidade Enxuta. A realidade atual apresenta mercados altamente competitivos e a busca incessante de melhoria de desempenho por parte dos gestores, visando melhores margens de lucro e redução de desperdícios. Tais práticas resultam, consequentemente, na diminuição de custos e em melhor retorno para os negócios. A delimitação do estudo ocorreu mediante a escolha de duas empresas que ocupam posições de destaque no setor de artigos esportivos: Nike e Adidas. Uma análise comparativa entre tais empresas, visto que há a adoção da fabricação enxuta apenas na Nike. A observação comparativa mediante os demonstrativos contábeis de ambas as empresas evidenciou melhor eficiência para a empresa com cultura lean. Portanto, o presente artigo consegue evidenciar resultados positivos por meio da adoção do Lean Manufacturing concomitantemente ao Lean Accountig como opções e diretrizes para a redução de desperdícios e melhor desempenho operacional que decorrem em resultados monetários melhores as organizaçãoes que decidem pela adoção a fabricação enxuta, com a implementação de novas práticas ao negócio.

Analysing the adoption of Lean production in remanufacturing industry

Purpose: This paper aims to analyse the challenges of lean manufacturing implementation in the remanufacturing industry. The research was undertaken in three types of remanufacturing company, torque converter, gearbox, and jet engine remanufacturers. This paper describes the characteristics of remanufacturing companies and compares them with the best practice company adopting lean manufacturing best practice: Toyota Motor Company. Through a comparison of the characteristics of the manufacturing environment, macro, and external condition, the challenges of adopting lean manufacturing are identified.Design/methodology/approach: This study utilised a case study method to analyse qualitative data collected from interviews, observations, and focus group discussions. Although case studies are typically used in inductive research, this study followed a deductive approach.Findings: The analysis demonstrated that remanufacturing companies experience challenges due to contextual differences to the benchmark company. The research found that there are some practices that are embedded in remanufacturing companies, but that the companies do not realise that these are lean manufacturing practices. On the other hand, there are a number of external factors that are beyond the remanufacturers’ control that hinder the adoption of lean manufacturing. In addition, the aftermarket business of remanufacturers has resulted in a number of distinctive macro condition characteristics that make the adoption of lean manufacturing more complex.Practical implications: Successfully addressing barriers to lean manufacturing adoption might enhance the performance of remanufacturing process. This is because the business of remanufacturing is not value creation, but capturing value from used products.Originality/value: This paper contributes to existing literature examining lean production in remanufacturing companies. It is novel in the sense that it is the first study examining lean production in the remanufacturing industry from organisational and managerial perspectives.

Objetivos y decisiones estratégicas operacionales como apoyo al lean manufacturing

The aim of this study is to identify coordination mechanisms among lean manufacturing tools and operations strategy. The study was carried out in seven companies of the textile sector located in the Valley of Aburrá, Colombia. A case study methodology is used. The methodology is based on a quantitative approach and a descriptive-correlational scope. Among the main results, it was found that operational profit became the main driver between delivery strategy objective, capacity strategy decision and the incorporation of lean philosophy in daily organisation activities. Furthermore, the optimising of organisational resources was achieved by the adoption of lean manufacturing. This also involves collaboration from different hierarchical levels of the organisation.

Does Lean Improve Labor Standards? Management and Social Performance in the Nike Supply Chain

This study tests the hypothesis that lean manufacturing improves the social performance of manufacturers in emerging markets. We analyze an intervention by Nike, Inc., to promote the adoption of lean manufacturing in its apparel supply chain across 11 developing countries. Using difference-in-differences estimates from a panel of more than 300 factories, we find that lean adoption was associated with a 15 percentage point reduction in noncompliance with labor standards that primarily reflect factory wage and work hour practices. However, we find a null effect on factory health and safety standards. This pattern is consistent with a causal mechanism that links lean to improved social performance through changes in labor relations, rather than improved management systems. These findings offer evidence that capability-building interventions may reduce social harm in global supply chains. Data, as supplemental material, are available at http://dx.doi.org/10.1287/mnsc.2015.2369 . This paper was accepted by Bruno Cassiman, business strategy.

Mapeamento do fluxo de valor e simulação para implementação de práticas lean em uma empresa calçadista

Geralmente, a implementação do Lean Manufacturing (LM) se inicia com o Mapeamento do Fluxo de Valor (MFV). O objetivo deste trabalho é apresentar a aplicação do MFV, associado à simulação, a fim de analisar os impactos da adoção do LM no desempenho de uma empresa calçadista. Então, realizou-se um MFV do estado atual e, por meio da implantação de elementos da abordagem lean, pôde-se construir o MFV do estado futuro. Diferentes cenários foram simulados para a implementação do estado futuro e tiveram seus resultados comparados. As etapas produtivas simuladas foram o transfer, o corte e a montagem, visto que se considerou que entre esses processos poderia ser estabelecido um fluxo unitário do produto. Após a simulação, o cenário que apresentou melhores resultados proporcionou um aumento de produtividade de 19% em relação ao estado atual, além de melhoria em todas as outras variáveis que foram comparadas. A aplicação da simulação como um elemento adicional do MFV ajudou a identificar as vantagens da abordagem conjunta, uma vez que a mesma possibilita testar diferentes alternativas e definir melhor o estado futuro e suas estratégias de implementação.

Evaluation and selection of lean resourced employee in the manufacturing industries using the TOPSIS-Simos method

Among modern manufacturing methods, lean manufacturing has been a dominant method used in many industrial sectors. The principle of the lean manufacturing is to eliminate the wastes present in various forms of the industry. The adoption of lean manufacturing in an industry could be identified by the leanness measurement through lean assessment. In lean assessment, the evaluator plays a vital role. Selecting the right person for the assessment will reduce the ambiguity, time consumption and computation time. Decision-makers play a vital role in lean assessment. Few studies have been found in the literature to select or identify the decision-maker. In this article, the TOPSIS-Simos method has been proposed to identify a lean resourced employee in the industry. The proposed method is case studied in the manufacturing industries. The lean resourced employee has been identified after computation. The proposed method could be applied to identify the lean resourced employee in all types of manufacturing industries.

Determinants and barriers to lean implementation in food-processing SMEs – a multiple case analysis

This study explored contextual or determining factors and their impacts on lean manufacturing in small- and medium-sized enterprises (SMEs) operating in food-processing industries. In order to get an in-depth insight into the real situation at the work floor, this study adopted a multiple-case-study research approach. The inherent characteristics of food industries, such as mandatory quality assurance requirements, low shelf life of food products, and the extremely volatile demand and supply presented barriers to lean manufacturing adoption. In addition, the challenges of ‘change’ in an SME environment are distinct from those faced by large organizations. The small size of the plant, the traditional setup, and inflexible layout make it difficult to implement lean manufacturing in food-processing SMEs. The knowledge of contextual factors influencing lean manufacturing adoption in food processing SMEs will be a contribution to current knowledge. Many studies have explored lean constructs and tools, while far fewer have explored the crucial element of actually implementing these. The study will also help practitioners to anticipate potential obstacles and take proper measures to deal with them during lean implementation.

Product wheels to achieve mix flexibility in process industries

Purpose – Mix flexibility is a critical manufacturing flexibility type needed to produce a company's range of products. Oftentimes, multiple products are produced on shared resources which require coordination mechanisms to ensure their effective utilization. This paper aims to explore the applicability of the product wheel concept as a coordination mechanism that can be used to manage shared resources in operational mix flexibility achievement in process industries. Design/methodology/approach – The product wheel concept is a construct from the theory of lean manufacturing adoption in process industries. This construct is applied as a sequencing coordination mechanism, where similar products are grouped together to run consecutively in a production schedule. A single case study is used to illustrate the development and evaluation of a product wheel design. Findings – The results show that the product wheel concept does achieve the aim of grouping similar products in the production schedule, and, as such, can be used to improve the production planning process through the reduction of the number of time-intensive changeovers without sacrificing product availability to meet customer demand. The product wheel, however, is not a mathematical optimization technique; but is instead a heuristic technique which requires the use of judgment and experience to achieve an optimal design. Originality/value – A theoretical contribution to the study of mix flexibility has been made, where the application of the product wheel construct presents a novel approach to the study of operational mix flexibility achievement, via the sequencing of products on shared manufacturing resources.

A VSM improvement-based approach for lean operations in an Indian manufacturing SME

The current economic environment in the Indian manufacturing industry is offering a perfect opportunity to SMEs of this country to develop and grow by acting as suppliers of large multinational original equipment manufacturers (OEMs). To meet the challenge of offering high standards of quality, cost and delivery (QCD) to these multinational OEMs, Indian manufacturing SMEs must implement effective approaches, such as lean manufacturing, to continually and systematically improve their operations. However, the academic literature indicates that the adoption of lean manufacturing and some of its tools, such as value stream mapping (VSM), by Indian manufacturing SMEs is feeble, or in many cases lean initiatives have been unsuccessful. This paper presents a successful application of VSM in an Indian manufacturing SME. The results of the study and operational improvements achieved indicate that the application of VSM is an effective