Lean Manufacturing Practices Research Articles

Lean Manufacturing Practices and Organizational Performance: A Literature Review

This literature review examines the relationship between Lean manufacturing practices and organizational performance across various industries. By analyzing recent research from 2020 to 2024, this study synthesizes findings on key Lean practices, their implementation challenges, and their impact on different aspects of organizational performance. The review highlights the evolving nature of Lean manufacturing in the context of Industry 4.0 and sustainable manufacturing. It also identifies gaps in current research and suggests directions for future studies. The findings indicate that while Lean practices generally positively influence organizational performance, their effectiveness depends on various factors including organizational culture, technological turbulence, and integration with other management approaches.

Unlocking potential for a circular bioeconomy transition through digital innovation, lean manufacturing and green practices: a review

PurposeToday’s businesses are looking for a circular bioeconomy (CBE) to develop a sustainable manufacturing process as industrial operations result in significant amounts of waste materials and the depletion of natural sources. The industry commonly applies techniques such as lean manufacturing (LM), digital innovations (DI) and green practices (GP) for operational and quality improvement. However, publications explaining how these technologies enable the CBE transition are scarce. This study examines CBE components, common practices of each technology facilitating the CBE transition, problems of solitary technology deployment as well as coupling technologies for the CBE transition.Design/methodology/approachA scoping review was conducted to analyse previous studies in this new field. The data collection is in a quantitative manner, but the data synthesis process follows a similar method of synthesising data in the grounded theory method, which includes familiarisation with the data, open-coding and finalisation of the themes.FindingsCritical components of CBE were identified as biobased goods, industry symbiosis, material resource efficiency, renewable energy, product lifecycle and sharing economy. GP is the most prominent in moderating the CBE transition. We identify each technology has coupled relationships (Lean-4.0, Green-Lean and Green-4.0) technologies facilitated by the circularity concept, which form the core pillars of enablers and advance the CBE paradigm.Research limitations/implicationsThis study demonstrates that combining lean principles with green technology and digital technologies can effectively decrease waste and resource usage in biobased manufacturing processes, therefore endorsing the concept of resource efficiency in circular bioeconomy models.Practical implicationsThe results allow entrepreneurs to strategically incorporate different existing technologies to meet CBE fundamental objectives by initiating it with dual technologies and facilitate industry professionals and regulators to support the improvement of environmental sustainability performance in the manufacturing industry. The management will be able to focus on the common practices across the technologies, which have a dual benefit for both operational and environmental performance.Originality/valueThe paper makes the first attempt to present the synergic impact of the three quality management technologies on a new concept of sustainability, CBE.

Lean Manufacturing Practices in Tanzania: Exploring Awareness, Training and Capital Investment

With the growing competition among industries in the world, manufacturing industries are now forced to adopt the Lean Manufacturing philosophy to improve their competitive abilities. The adoption of the philosophy is very low in developing countries such as Tanzania, as is demonstrated with 1% of publications and the lack of knowledge and capital for Lean Manufacturing implementation causes this. Furthermore, the contribution of the sector to the Gross Domestic Product in Tanzania is low and stands at 8.4%. The study wants to bridge the gap in training, capital and awareness of Lean Manufacturing in Tanzania. Survey and purposive sampling techniques were adopted in the study. A structured questionnaire was used to collect responses from 243 manufacturing industries of all sizes. Descriptive and inferential statistics were analysed with SPSS version 27.0.1. The results demonstrated that there is inadequate training for micro and small industries as more than 80% have not received any training, have inadequate funds whereby more than 95% have not allocated funds and low awareness with a mean score of below 3 out of 5. The status is contrary in medium and large industries, with more than 75% training provision. It was also revealed that 90% of large industries have allocated funds while for medium ones it is more than 39% and the awareness for Lean Manufacturing is high as they have a mean score of above 3. The Lean practices with high levels of awareness to all manufacturing industries are 5s, concurrent engineering and visual management. The low level of awareness, training and insufficient capital for Lean Manufacturing affect the adoptions of the philosophy in Tanzania. Therefore, the study will assist practitioners and policymakers in setting strategies for bridging the gap in the adoption of Lean Manufacturing in developing countries such as Tanzania.

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.

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.

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.

Effects Of Lean Manufacturing Practices On Operational Performance

Lean manufacturing is a concept of process improvement in production management which focuses on waste elimination. This paper explores relationships between lean manufacturing practices and operational performance. Using data collected from 55 manufacturing companies in Tasikmalaya city. Lean manufacturing were measured by five dimensions: production flow management, customer focus, process management, workforce management, and supplier management. Operational performance comprises four dimensions: cost, quality, lead-time, and flexibility. The findings are that all dimensions of lean manufacturing are significantly related to on operational performance. Production flow management has a higher level of significance in large enterprises compared with SMEs, whereas for customer focus there is a higher level of significance in SMEs compared with large enterprises. Process management, supplier management and workforce management have much lower level of significance for both SMEs and large enterprises.

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.

Sustain or perish: how lean manufacturing practices predict the sustainable performance of manufacturing SMEs? A moderated mediation analysis

PurposeThis paper aims to explore how lean manufacturing practices (LMPs) predict sustainable performance (SP) in the context of manufacturing small and medium-sized enterprises (SMEs) in less developed countries, like Yemen. In particular, it investigates the mediating effect of corporate social responsibility (CSR) under different levels of competitive intensity (CI).Design/methodology/approachHierarchical regression analysis was used to analyze data gathered from a survey of 259 Yemeni manufacturing SMEs.FindingsThe findings confirm that LMPs affect CSR, which in turn affects SP. This study also confirms that LMPs have a positive indirect effect on SP through CSR, which diminished in the presence of CI.Practical implicationsThis study provides useful insights for policymakers and firms’ managers, who are anticipated to show a higher commitment to CSR in their firms when adopting LMPs to enhance their firms’ SP, especially under a low level of CI.Originality/valueThis paper contributes to expanding knowledge on the effect of LMPs on SP through CSR constrained by the level of CI.

Gamification Approach for Interactive Learning of Lean Manufacturing Activities

The gamification approach is popular method in education as it has been widely utilized in many fields. The project focuses on designing a game for interactive learning of lean manufacturing activities to create an alternative learning method that would gain interest and efficiency in learning. Integration of gamification approach and interactive learning method was used to illustrate a virtual lean manufacturing education and training by means of users’ interaction towards provided interactive learning materials and participation in playing the designed game. Input of the project which is learning materials was developed by analysing numerous articles regarding common lean manufacturing tools and practices. Interactive elements such as animation, sound effects, lecture voice, and videos were applied in each learning material to deliver an adequate understanding of each topic. Construction of the game platform is being developed using ActivePresenter software which includes simulation videos of the production line using FlexSim software to visualize a real production floor which provides a clearer picture of the production system for users. The game should include a basic assessment of lean manufacturing practices by considering its complexity and difficulty level for users with inadequate or does not have experience in the field. The outcome of the project is expected to successfully design a basic game platform for lean manufacturing education by means of interactive learning. Users will be able to learn lean manufacturing systems using the designed interactive learning materials included in the games and self-assess themselves as the game publishes the correct and best answer option in case they answer wrongly.

The effect of lean manufacturing practices on employees’ well-being mediated by job characteristics

PurposeBased on the principles of positive psychology, this study aims to investigate the mediating role of job characteristics (task, knowledge, social and work context) in the connection between lean manufacturing (LM) practices and employee well-being.Design/methodology/approachEmployee well-being, encompassing job satisfaction, organizational affective commitment and work involvement, is conceptualized as a second-order construct. Using a proposed model, an online survey was administered to 520 participants across 23 operational sectors categories of the Brazilian manufacturing industry. The data is processed using structural equation analysis.FindingsThe research shows that the relationship between LM practices and employee well-being is partially mediated through three out of the four work characteristics (task, knowledge and social). In addition, LM exerts a direct and significant influence on employee well-being.Practical implicationsThis study contributes to practical insights by encouraging industrial managers to refine their managerial work design. It highlights the importance of appropriately dimensioning tasks, nurturing social skills to enhance interactions and task execution and optimizing physical facilities to counteract potential initial-stage work intensification during LM implementation.Originality/valuePrevious research about organizational behavior extensively examines happiness at work, focusing on constructs such as well-being, satisfaction, commitment, engagement and motivation, but there is a lack of studies assessing employee well-being in the lean context, particularly from a positive perspective.

Integrating industry 4.0 and lean manufacturing for a sustainable green transition: A comprehensive model

The integration of Industry 4.0 (I4.0) technologies and Lean Manufacturing (LM) principles has emerged as a significant strategy for industries seeking to improve precision, customization, competitiveness, and environmental sustainability. However, existing literature lacks a comprehensive model that incorporates these approaches and guides companies towards a green paradigm (GP) transition. This study aims to address the gap in literature by developing a comprehensive model that integrates I4.0 and LM practices and examines how this integration can enhance companies' ability to achieve a green transition. A Systematic Literature Review was conducted to identify 27 critical variables related to I4.0, LM, and GP. The ISM-MICMAC method was applied for analysis. Validation of the model was performed through interview with a sample company. The developed model provides a comprehensive framework for integrating I4.0 and LM practices to facilitate companies' transition towards environmental sustainability. The analysis revealed critical variables and their interactions, highlighting areas of focus for organizations aiming to adopt a green paradigm. The integration of I4.0 and LM practices offers significant potential for enhancing companies' ability to achieve environmental sustainability goals. By identifying critical variables and their relationships, this study provides valuable insights for organizations seeking to navigate the transition towards a green paradigm. This research contributes to the existing literature by presenting a novel model that bridges the gap between I4.0, LM, and environmental sustainability. The findings offer practical guidance for industries aiming to leverage technology and operational strategies to address sustainability challenges.

The Impact of Lean Manufacturing Practices in Enhancing Sustainable Performance through Lean Culture: Field Study at the General Company for Food Products – Baghdad

The study aimed to determine the effect of lean manufacturing practices in enhancing sustainable performance by mediating the lean culture in the General Company for Food Products in Baghdad, the field of study represented by the factories (Al-Maamoun, Al-Rasheed, and Al-Amin), where the study included the independent variable of lean manufacturing practices in their dimensions (comprehensive productive maintenance, map). Value flow, production on time, speed of preparation and preparation) in achieving sustainable performance in its dimensions (economic performance, social performance, environmental performance) by mediating the lean culture in its dimensions (continuous improvement, organizing the work site, reducing waste, and lean thinking). The study attempted to answer the questions that express the problem of the study, including: Is there an effect of lean manufacturing practices and the lean culture in achieving sustainable performance? The questionnaire was distributed to a sample of technicians in the company’s factories in the field of study. The study relied on the questionnaire as the main tool for collecting data through a random sample that included (218) technicians working in the factories under study. Some statistical methods were used for the two ready-made programs (SPSS, v.28, AOMS, V.26(. The study results that the primacy of the variables based on their relative importance, as they were respectively (lean culture, lean manufacturing, and sustainable performance). The results of the study showed that there is an effect of lean manufacturing practices in sustainable performance through the lean culture, The Food Industries Company was able to reduce unnecessary activities by using a lean culture to reduce waste, and this led to improving and sustaining performance in the company’s field of study.

Impact of Lean Manufacturing Practices on Waiting Time of Patients in Outpatient Department (OPD): A Study in the Sri Lankan Public Healthcare Industry.

This study aims to explain the impact of lean manufacturing practices on waiting time of patients at the outpatient department (OPD) in the Public hospitals. Cross-sectional data using a survey sample of 384 patients in the Kandy public hospitals with a satisfied random sampling were used. Data were analyzed using SPSS software. This study covers the four independent variables of lean manufacturing practices namely: 5S, visual management, kaizen, and Just in Time. The dependent variable is waiting time. The measurement instrument for lean manufacturing practices and waiting time was developed from comprehensive literature reviews. Results indicate that there is a negative significant impact of lean manufacturing practices on waiting time of patients in outpatient department (Beta = -0.626 & p=0.000). Therefore, these findings suggest that the theories of lean manufacturing and the knowledge-based view providing implementation of lean manufacturing practices can reduce waiting time for patients in outpatient department.

Design of an improved layout for a steel processing facility using SLP and lean Manufacturing techniques

Implementing lean manufacturing practices in the systematic layout planning (SLP) process for improving facility layouts in various industries is essential. This approach enhances material handling processes and effectively manages space utilization. An efficient plant employing systematic layout planning leads to improved resource utilization and facilitates the integration of lean manufacturing techniques such as value stream mapping, 5 S, Ohno’s 7 wastes, and cellular manufacturing. This research article presents a case study on a steel processing plant in Dubai with an area of 160 m × 160 m, where systematic layout planning and lean manufacturing techniques were applied. The factors considered included space and material flow optimization, incorporating layout alternatives based on systematic layout planning principles along with lean manufacturing techniques. The study revealed a 34% reduction in material flow and an efficient overall space utilization improvement of 26%. Additionally, cost analysis validation was conducted.

IMPROVING EMPLOYEE AND WORKPLACE PERFORMANCE VIA LEAN MANUFACTURING PRACTICES: A CASE STUDY IN TEXTILE COMPANY

This study explores the possibility of enhancing employee and workplace performance by implementing lean manufacturing practises in a textile industry. It addresses the the limited availability of empirical data concerning lean practices, with a particular focus on the textile industry. Qualitative approaches were employed involving direct observations and in-depth interviews with important stakeholders, followed by a thematic analysis of the data. The findings highlight the effects of lean manufacturing practises (Just-in-Time (JIT), flexibility, and continuous improvement) on worker performance, workplace productivity, quality, and overall organisational performance. The outcomes of this research offer valuable insights and practical recommendations for textile companies aiming to enhance their employee and workplace performance through the adoption of lean manufacturing practices. Such implementation will help to reduce lead time, improve customer satisfaction, and increase productivity and efficiency.

Achieving social sustainability through lean manufacturing practices: Insights from structural equation model and system dynamics

The relationship between Lean Manufacturing (LM) practices and their impact on Social Sustainability (SOS) remains an area that warrants further investigation, especially in developing countries and industrial sectors with a high level of manual work in which there are many occupational diseases, where well-being is required by labor laws, such as Mexican maquiladora (MM) companies. Recognizing this research gap, this study explores and assesses the influence of LM practices on MM's SOS. The study proposed and evaluated a structural equation model (SEM) with eight hypotheses tested statistically using information obtained from 411 responses to a questionnaire distributed across the MM. WarpPLS software (version 8.0) was employed to validate the SEM and STELLA ARCHITECT V3.0.1, to evaluate a system dynamics model to simulate the longitudinal behavior of LM practices on SOS. The findings underscore the critical role of the 5 S methodology in facilitating the adoption of practices, such as Total Productive Maintenance, Quick changeover, and One-piece Flow, exhibiting positive repercussions on SOS. Notably, the study's estimates suggest a timeline of approximately 6.5 years to attain 100% implementation of these tools, while achieving complete SOS may extend to approximately 11.75 years. It is imperative to approach these projections cautiously, because of the dynamic nature of business environments, wherein unforeseen alterations may significantly influence these timelines. These estimates offer valuable insights into the potential temporal dynamics of LM practices and SOS implementations in industrial contexts.

Investigating the influence of lean manufacturing approach on environmental performance: A systematic literature review

AbstractThe growing emphasis on environmental sustainability has drawn considerable attention from both academia and industry practitioners. Factors such as escalating energy costs, heightened environmental degradation, and a burgeoning market demand for eco-friendly practices have compelled businesses to reassess their strategies through a green lens. Given that Lean principles are rooted in optimising operations to minimise waste across design and production processes, their synergy with the green paradigm is evident. However, despite the intuitive connection between Lean methodologies and environmental sustainability, the scholarly exploration of their impact remains largely underdeveloped. This research seeks to bridge this gap by conducting a comprehensive systematic literature review to dissect the current understanding of Lean manufacturing practices and their influence on environmental sustainability performance. The selected papers were meticulously screened and grouped into three clusters using the PRISMA diagram methodology. The primary objective was to discern the tangible effects of Lean practices on eco-efficiency performance and explore integrating Lean manufacturing principles with broader sustainable manufacturing approaches. A structured matrix was created to categorise and visualise the identified impacts gleaned from the initial articles. Nevertheless, the review revealed significant gaps in understanding, particularly regarding the factors that shape the efficacy of Lean manufacturing tools in enhancing eco-efficiency performance. The findings underscore the need for further research to unravel these complexities and delineate the mechanisms through which Lean practices contribute to environmental sustainability. Several avenues for future research have been delineated, focusing on how Lean manufacturing practices can be leveraged to support eco-efficiency performance effectively. While the preliminary findings shed light on the promising intersection between Lean principles and environmental sustainability, they also underscore the imperative for continued scholarly inquiry to unlock the full potential of Lean methodologies in fostering a greener industrial landscape.

Impact of lean manufacturing practices on the performance of manufacturing industries

In this paper, we aim to check the impact of lean manufacturing practices on the performance of the manufacturing industry in Pakistan. The three practices involve customer involvement, supplier involvement, and 5s and their effect on the industry's performance. For this purpose, we used a random sampling technique with a sample of 20 questions, a question-based questionnaire designed under the supervision of expert supply chain specialists from different manufacturing industries and authentic research journals. The key finding of this research paper is that we have seen the positive significance of lean practice on the performance of Pakistan's manufacturing industry.

Lean manufacturing practices in an educational institution to improve the operational efficiency of a machine shop

The lean manufacturing approach is employed across several sectors to minimise waste and extend its ideas to institutional settings. The objective of this work is to provide instruction to aspiring engineers regarding the implementation and utilisation of lean tools. The machine shop of an engineering college utilised several tools, including 5S, standard work, and machine maintenance. The students were educated on the difficulties and achievements associated with the implementation of lean ideas across several tiers within the machine shop. The findings indicate that it is imperative to remove non-value-added operations, commonly referred to as Muda, in any manifestation inside the shop. A sequence of 5S audits was carried out to facilitate the enhancement of KAIZEN initiatives and uphold the shop's commitment to lean principles. The determination and assessment of the influence of lean tools on the Machine Shop were conducted through the utilisation of a questionnaire employing a five-point Likert scale. Following the implementation of lean principles, there has been a notable enhancement in several aspects. Specifically, there has been a 6.6% improvement in space utilisation, a substantial 95.12% increase in safety measures, a significant reduction of 83.3% in machine failure occurrences, and a noteworthy decrease of 80.2% in the time required for tool search.