Lean Manufacturing Practices Research Articles

Implementing Industry 4.0 and lean practices for business performance in manufacturing: Case of Malaysia

Manufacturing industries had embraced the trend of conceiving a robust manufacturing system and enhancing business performance with the implementation of Industry 4.0 digital technologies and lean manufacturing practices. Despite multiple studies being conducted to identify the correlation between Industry 4.0 digital technologies, lean manufacturing practices, and business performance, ambiguous and conflicting statements are often being debated among researchers. Hence, this study aims to provide empirical evidence gathered from Malaysian manufacturing industries using questionnaires to investigate and model their correlation and explore the mediating influence of Industry 4.0 digital technologies on lean manufacturing practices and business performance using PLS-SEM. Consequently, the findings from 124 respondents were compared with prior studies and revealed that both Lean Manufacturing Practices and Industry 4.0 Digital Technologies are positively correlated with one another, and they positively influence business performance, which findings are coherent with prior studies and fortifying the urgency of implementing both concepts for business performance enhancement. Moreover, this study successfully revealed that Industry 4.0 digital technologies mediate lean manufacturing practices and business performance proving the importance of Industry 4.0 to solving Lean’s limitation, which is not studied in prior studies. In addition, the framework in this study is more practical in providing appropriate theoretical and managerial insights for future action and works due to its medium predictive power associated. In a nutshell, this study effectively implies the substantial roles and reinforced the pragmatisms of implementing both lean manufacturing practices and Industry 4.0 digital technologies concurrently for business excellence.

Towards Lean Manufacturing in Developing Countries: Research Gaps and Directions in Tanzania

In the current knowledge-driven economy, many industries across the globe are forced to adopt manufacturing technologies such as lean manufacturing to remain competitive in the globalized world. Despite the increase in lean manufacturing implementations, the adoption rate in Tanzania is very low and estimated to be 8 percent. Likewise, the sustainability of lean manufacturing tools and practices is still questionable, which shows the need to develop lean maturity models. To date, several lean maturity models have been developed but there is a lack of maturity models that consider different levels of manufacturing industries. The study presented in this paper focused on the pre-implementation, implementation, and post-implementation phases of lean manufacturing. To achieve this aim, a systematic literature review and social network analysis using VOS viewer 1.6.18 were conducted. The literature was obtained from four academic databases: Emerald, Elsevier, Springer, and Taylor and Francis. The search covered the period from 2010 to 2022. Of the 100 publications analyzed on lean manufacturing, only 1 percent is from low-income developing countries and 5 percent of publications from Africa. The study has identified that there are few numbers of research publications on lean manufacturing in Africa and low and lower-middle-income developing countries in general, as a result there is a low rate of implementation of lean manufacturing in low and lower-middle-income developing countries. It is recommended that more studies on the drivers and barriers, critical success factors, and lean assessment be conducted in developing countries.

Lean manufacturing practices for operational and business performance: A PLS-SEM modeling analysis

Objective The main objective of the study is to empirically investigate the influence of lean manufacturing (LM) practices on the operational and business performance of manufacturing companies in Oman. Methods Empirical data on LM practices and performance were collected using a self-administered structured survey questionnaire and the sampling frame was manufacturing companies in Oman. In total 300 questionnaires were distributed among 185 companies and a total of 107 with a response rate of 35.6 percent. Findings The statistical analysis obtained from structural equation modeling found that lean manufacturing practices can explain operational performance, however, were unable to benefit overall business performance. Out of eight LM practices considered, small-lot production and quick setups were found to be the most adopted practices in manufacturing companies. Novelty Even though LM has become a fundamental aspect of industrial manufacturing processes; little is known about its impact on performance. This study adds value to the literature by examining the key LM practices-performance relationships within the manufacturing companies in Oman. These findings have significant implications for improving manufacturing organizations' operational and business performance through lean manufacturing strategies.

Productivity improvement through the development of sustainability metrics in wire manufacturing industry

Lean manufacturing practices are currently becoming the driving force for the development of new strategies for green and sustainable manufacturing. Conventional value stream mapping (VSM) can be extended to sustainable value stream mapping (Sus-VSM), which assesses not only economical aspects but also environmental and social dimensions of sustainability. The productivity of the industries can be enhanced by mapping the current practises and scopes so that improvements can be easily identified and standardised. This paper deals with the development and assessment of sustainability metrics in four dimensions of sustainability to improve the productivity of the manufacturing industries. The sustainable VSM is validated in a wire manufacturing industry and various techniques of improvement are suggested to the industry. Life-cycle assessment (LCA) technique is done using the Solidworks sustainability module to quantitatively assess the environmental impacts of all the stages of a product's life. Analytical hierarchy process is used to analyse, identify and prioritise various metrics, likely to have a greater impact on productivity and sustainability.

The Era of Industry 4.0 Technologies and Sustainable Organizational Performance of Pakistan's Garment Industry: The Role of Lean Manufacturing and Green Supply Chain Management Practices with the Moderating Effect of Sustainability Culture

The Era of Industry 4.0 Technologies and Sustainable Organizational Performance of Pakistan's Garment Industry: The Role of Lean Manufacturing and Green Supply Chain Management Practices with the Moderating Effect of Sustainability Culture

Применение методов бережливого производства для улучшения управления производственными процессами на химическом предприятии

This article discusses lean manufacturing methods aimed at improving the management of production processes in a chemical plant. The object of the study is the concept of lean production, the subject is the use of its methods in the production of low fission polyethylene in the public joint-stock company Kazanorgsintez. The article provides a brief overview of the methods and tools of lean manufacturing, which are most widely used in Russian industrial enterprises. Based on the example of low-density polyethylene production in Kazanorgsintez Public Joint-Stock Company, recommendations have been developed on the use of lean manufacturing methods to optimize production processes, in particular, the Just-inTime principle, which is implemented through the use of the automated KANBAN system (at the stage of production of low-density polyethylene) and the "pull" model (on the example of low-density polyethylene storage). As a result of the study, the prospects for the introduction of methods and tools of lean production at a chemical enterprise are shown.

Lean manufacturing practices mediating the relationship between outsourcing and firm's profitability

Lean manufacturing practices mediating the relationship between outsourcing and firm's profitability

A Bayesian Best–Worst approach for assessing the critical success factors in sustainable lean manufacturing

Over the last few decades, industries in emerging economies have been encouraged to embrace sustainable lean manufacturing (SLM) practices to lower operational expenses, eliminate wastes, conserve resources, improve customer satisfaction, and focus on the economic, environmental, and social aspects of sustainability to maximize productivity. So far, no study has explored the critical success factors (CSFs) facilitating the furniture manufacturing industry’s embrace of SLM. This study investigated the CSFs for implementing SLM in the furniture manufacturing industry of an emerging economy like Bangladesh. First, with the help of a literature review and consultation with experts, a total of sixteen most significant CSFs for implementing SLM in the furniture industry was identified. Then, the identified CSFs were clustered into three criteria groups or clusters — organizational and governmental cluster, supply chain, inventory, resource management cluster, and performance and technological cluster, based on the suggestions from the experts. Finally, we employed the Bayesian Best–Worst method (BWM) to evaluate the importance of these CSFs. This study shows that sustainable resource utilization and management reduces lead time and non-value-adding activities, adequate support from top management, and adoption of disruptive and emerging technologies are the top four crucial CSFs to implement SLM effectively in the furniture manufacturing industry. These findings can assist industry professionals and regulators in making efficient action plans to capture this competitive but booming market while ensuring a sustainable future for the next generation.

An empirical examination of SMEs sustainable performance through lean manufacturing

AbstractIn the modern business world, manufacturing entities seek the modern way of production, which can help them to minimize the wastage of material. To minimize the wastage of materials in manufacturing entities, use different modern techniques, and one of the modern techniques is lean manufacturing. This study aims to explore the relationship between lean manufacturing and the sustainable performance (SP) of the firm. For this purpose, data were collected from SMEs working in Pakistan. Results elaborate that four lean manufacturing practices, that is, process and equipment, product design, supplier relationship, and customer relationship have a positive and significant impact on SP, but the impact of planning and control and HR practices could not be verified. Moreover, green supply chain management (GSCM) found a mediator between HR practices, product design, supplier relationships, customer relationships, and SP. Outcomes of this study provide the higher management of SMEs with a way forward to implement modern techniques within their organizations to minimize the wastage of material during the manufacturing process. Furthermore, this study will cover the deficiency in the literature about the mediating role of GSCM between lean manufacturing and sustainable performance.

Analysing the Barriers for Implementation of Lean-led Sustainable Manufacturing and Potential of Blockchain Technology to Overcome these Barriers: A Conceptual Framework

Micro- Small and Medium Enterprises (MSMEs) are very significant for a country’s economy due to their contribution to manufacturing, sales and Gross Domestic Product (GDP) growth. The global market competition and standards have been compelling MSMEs to improve quality, reduce waste, improve environmental performance and optimize the cost of products by implementing sustainable practices. The combined approach of lean and sustainable practices can help MSMEs to minimize emissions from waste and manufacture low-cost products with energy-efficient technology. However, MSMEs face many challenges while implementing lean and sustainability tools. Therefore, the main aim of this study is to identify the barriers which create obstruction in the implementation of lean-led sustainable manufacturing practices in Indian MSMEs and prioritize them by calculating their weights. The study also proposes a framework for the integration of blockchain technology in the supply chain to overcome the barriers for the implementation of lean and sustainable manufacturing practices. Extensive literature reviews and experts’ opinions have been used to identify the critical barriers for the implementation of lean-led sustainable manufacturing practices in manufacturing firms. A total of forty barriers were selected and further categorized under seven main categories of barriers. The main category barriers and subcategory barriers are ranked based on the weight obtained through Best Worst Method (BWM). The ranking results are further analysed to assess the reliability and robustness using sensitivity analysis. The study reveals that economic and managerial barriers, knowledge and awareness barriers and organizational barriers are the most prominent category of barriers for lean and sustainable manufacturing. The study found that ‘Lack of awareness among customers towards sustainability’, ‘initial capital investment and low financial profit’, ‘lack of knowledge about potential benefits from sustainable products and practices’ and ‘resistance to change due to past failure’ are the most critical barriers for implementation of lean-led sustainable practices in Indian MSMEs. The study has analysed the features of blockchain technology and their effect on the performance of lean-led sustainable supply chain. The findings of the study will help managers and practitioners in Indian MSMEs from certain perspectives to develop an effective and efficient strategy to overcome these barriers and become sustainable. Therefore, this study provides valuable insights for researchers and practitioners.

Integrating S-ERP systems and lean manufacturing practices to improve sustainability performance: an institutional theory perspective

PurposeThis paper aims to investigate the impact of integrating Sustainable Enterprise Resource Planning (S-ERP) systems and lean manufacturing (LM) practices on sustainability performance, especially in Egypt as an emerging country.Design/methodology/approachThe authors carried out an experimental study with a sample of 144 professional accountants of MPA, MBA and DBA students at two of the top universities in Egypt.FindingsThe results provide significant evidence that the integration of S-ERP systems and LM practices implementation improve sustainability performance. However, there is no significant evidence that S-ERP adoption contributes to the success of LM practices implementation.Research limitations/implicationsBecause of the chosen research approach, this study is limited to use of a laboratory experiment design. Empirical evidence based on quasi experiments on a field setting would add value to the current literature.Practical implicationsFindings provide practical insights for the manufacturing sector managers into the benefits of integrating S-ERP systems and LM practices for sustainability performance improvement (e.g. reducing cost and waste, increasing operational efficiency). For ERP vendors, findings highlight how ERP vendors introduce “enablers” that incorporate LM best practices into their ERP systems and also how those vendors conform to the software sustainability criteria in the design of ERP applications.Originality/valueContrary to previous studies that addressed the individual impact of S-ERP systems and LM practices on performance, this paper experimentally gives an indication of the impact of concurrent implementation of S-ERP and LM practices on sustainability performance, especially in developing countries.

Investigating the Impact of Lean Manufacturing Practices on Operational Performance

In order to remain competitive and resilient in business, manufacturing companies must improve their operational performance continuously. Superior performance can no longer be achieved with abundance of time, resources, and money, but the right approaches and tools will allow companies to perform better with greater flexibility. As manufacturing companies try to identify the most beneficial approach, many conclude that Lean Manufacturing (LM) practices are the way to go. LM practices may seem promising at first, but its implementation doesn’t always produce the desired results, and not all LM tools are universally applicable. Choosing the wrong tool might throw off the entire process though initially it meant to improve. Therefore, this study aims to determine the most used of LM tools and how these tools can impact the operational performance. A total of eleven completed responses were collected in the survey through convenience sampling method. Empirical results through descriptive analysis revealed that usage of LM tools such as 5S and Kaizen can lead companies in improving their processes. While lack of knowledge and resistance to change are the major barriers in practicing LM.

Status of Lean Manufacturing Practices and Its Influence on the Adoption of Industry 4.0 in the Malaysian Furniture Industry

Status of Lean Manufacturing Practices and Its Influence on the Adoption of Industry 4.0 in the Malaysian Furniture Industry. Lean Manufacturing practices is being promoted throughout the manufacturing industry in the country to boost industrial productivity. Therefore, a study was carried out to determine the level of adoption, benefits, and challenges faced by furniture manufacturers in adopting LM. Further, it was also evaluated if LM facilitated the transition towards Industry 4.0 adoption. The questionnaire-based survey involved 484 furniture manufacturers, of large-size and SMEs. The results found that the adoption of LM was prevalent among large-sized companies, and LM improved product quality and customer satisfaction, while reducing manufacturing lead time in the companies. The 5S method of work place organization, process mapping and waste reduction and elimination were the most common LM tools adopted by the companies. On the other hand, the major challenges encountered when implementing LM were lack of know-how, backsliding to old work ways, and resistance to adopt among the employees. The result also revealed that companies practicing LM also suggested that they were more prepared to adopt Industry 4.0 technologies, as the practice of LM has not only reduced waste on the production shopfloor, but also improved the information flow that is important for digital tools of Industry 4.0.

The Significant of Lean Practice on the Sustainability Performance in Automotive Manufacturing Industry

This study attempts to evaluate the significant of lean practices on the sustainability performance in automotive manufacturing industry. Lean practices are typically used to eliminate waste that are produced by defects, waiting time, overproduction, extra motion, extra processing, excess inventory and unnecessary transportation. Meanwhile, sustainability performance is defined as the alignment of financial, environmental, and social objectives in the conduct of fundamental business operations with the goal of maximizing value. The study was conducted in the form of a questionnaire survey and the statistical analysis was carried out based on collected data. This study only focuses on automotive manufacturing industry in the area of peninsula Malaysia. Statistical Package for Social Sciences (SPSS) is applied to answer the research objectives and to test the hypotheses. The results show the high levels of Cronbach's Alpha indicate that the questionnaire data are valid and dependable. All the companies have significant gain more in terms of environment sustainability performance by adopting lean techniques. The study also indicates the most tools that had been implementing among the four companies are 5S, kaizen, kanban, employee commitment and teamwork. Through the multiple regression analysis, the result indicates that the lean practices have significant and positive effect on sustainability performance in automotive manufacturing industry. The current study also benefits manufacturer by providing information on the extent of lean manufacturing practices and their impact on three bottom lines (TBL) sustainability performance, allowing helping their company achieve long-term economic, environmental, and social improvements.

Evaluation of Lean Manufacturing Practices in an Automotive Component Manufacturer

Purpose: This study aims to evaluate lean manufacturing (LM) practices used in a company in the automotive component industry located in Polo Industrial de Manaus (PIM), a manufacturing hub in the city of Manaus. Theoretical framework: The AME Lean Assessment instrument was used as the research framework in this study. This instrument was developed by the Association for Manufacturing Excellence (AME) to benchmark where a company is on its lean journey.Design/methodology/approach: An exploratory case study was carried out, and since a more detailed study was needed, a research framework was used, composed of 14 attributes on lean manufacturing.Findings: The findings point to a high level of LM practices adopted by the company, in addition to allowing the practical application of the fundamental concepts to be observed for the Toyota Production System (TPS) at Polo Industrial de Manaus. The findings have increased the understanding in organizational behavior relating to LM.Research, Practical & Social implications: the study contributes to the body of knowledge on lean manufacturing considering its application in the Amazonian context. The study has made a substantial contribution to the understanding of lean manufacturing in the context of an important industrial park in Brazil. Originality/value: Originality is the adoption of a research framework for evaluating lean manufacturing practices in an Amazonia context, allowing the specific characteristics of lean manufacturing to be understood in Amazonia, from an in-depth case.Keywords: Lean manufacturing; Lean Assessment; Industry; Automotive components; Amazonas.

Pengaruh Praktik Lean Manufacturing Terhadap Profitabilitas Melalui Minimisasi Persediaan di Industri Elektronik dan Otomotif Indonesia

This study aims to analyze the impact of lean manufacturing practices on profitability mediated by inventory minimization in the electronics and automotive industries in Indonesia. Given the critical role of lean manufacturing and inventory minimization to increase a company's profitability, a company needs to implement lean manufacturing practices to eliminate waste at the operational level. A low but adequate inventory level will reduce costs borne by the company to contribute to the company's profitability. This research is a replication of Nawanir et al. (2013) study. In the current study, the samples taken were 204 large manufacturing companies that refer to the 2015 Indonesian Standard Business Field Classification (KBLI), with codes KBLI 26 and 29. Company data were obtained from a directory provided by the Data and Information Center of the Ministry of Industry of the Republic of Indonesia (Pusdatin Ministry of Industry). Hypothesis testing using the Partial Least Square technique (smartPLS 3.0 software) shows that lean manufacturing practices implemented as a whole by the company especially in the electronics and automotive industries can minimize inventory and ultimately contribute positively to the company's profitability. Keywords: electronic and automotive industries, inventory minimization, lean manufacturing, profitability

Hybrid Lean Practices Integrated with IR 4.0 and Sustainability in Malaysia Food and Beverages Companies: Conceptual Framework and Hypothesis Development

The growing competition within manufacturing practices has motivated organizations to upgrade their conventional production system to a smart, sophisticated systems. This study evaluates the impact of lean manufacturing practices (LMP) and industrial revolution 4.0 technologies on sustainability in the food and beverages industry. Past literature has revealed that lean practices significantly affect sustainable performance. However, the integrated effects of lean manufacturing practices and IR 4.0 technologies on sustainable performance have not been examined empirically. In order to fill the void of this gap, this study intends to have a preliminary investigation of the combined effects of LMP and IR 4.0 technologies on sustainable performance, specifically in the food and beverages industry. Furthermore, the study aims to confirm the future direction of the food industry that is recently employing new technologies in its manufacturing systems. This study is underpinned by the theories of contingency and practice-based view by highlighting the contributions of operations management practices to implement successful strategies in enhancing sustainability performance in food and beverages companies through performance variations. This study extends the current literature on IR 4.0 technologies and lean manufacturing practices as enablers of economic, environmental, and social sustainability. Also, the study provides implications and future direction for industry consultants, practitioners, and academicians.

The Challenges of Lean Transformation and Implementation in the Manufacturing Sector

In this study we explored the challenges involved in Lean Transformation and implementation in the manufacturing sector. Using survey data from 50 North American manufacturing organizations, we examined the challenges involved in implementing and sustaining Lean Manufacturing (LM) principles and practices in production processes. The fuzzy analytic hierarchy process (FAHP) and the fuzzy analytic network process (FANP) were used to rank the considerable challenges observed in these organizations. We concluded that the need for a change in organizational culture was the major barrier to Lean implementation. It is challenging to sustain Lean without a culture shift and a clear direction set by the organization’s leadership team. The originality of the paper relates to prioritizing the cultural aspects of organizations as a major barrier to LM implementation. Other challenges encountered during Lean implementation in the manufacturing industries were related to management support, technical knowledge, and employee resistance to change. Early identification of these challenges enables companies to question their capabilities before implementing the Lean philosophy. In this study we used results obtained from 50 manufacturing companies in North America, representing a subset of manufacturing organizations. As a result, it must be interpreted based on the data acquisition method and the study’s sample size.

An occupational health and safety management system framework for lean process industries: an interpretive structural modelling approach

Purpose The manufacturing sector has been observing various benefits by the implementation of lean manufacturing practices. However, the manufacturing sector has neglected the significance of health and safety management system implementation. The purpose of this research is to propose and validate an occupational health and safety management systems (OHSMS) framework based on critical success factors and their relationships in the lean manufacturing organizations. Design/methodology/approach A critical literature review was conducted to identify the success factors of OHSMS. Subsequently, a questionnaire survey and semi-structured interviews were conducted with experts from process industries to consolidate the critical success factors. After consolidating the critical success factors, relationships among critical success factors were established with the help of interpretive structural modelling using a team of 12 experts from industry and academia. These established relationships helped in proposing the hierarchical implementation framework. Finally, the validation of the proposed implementation framework was carried out using structural equation modelling (SEM). Findings This study has identified nine broader critical success factors for implementation of OHSMS in lean manufacturing organizations, especially the process industry. Subsequently, this study has proposed an OHSMS framework with nine broader critical success factors to implement in lean manufacturing organizations. Finally, the proposed framework has been validated using SEM with an appropriate sample size. Practical implications This study is helpful to the organizations to implement OHSMS without losing the essence of lean manufacturing strategy. This study has proposed a framework for implementation of OHSMS in the lean manufacturing organizations, especially process industry sector. This study also provided confidence to the organization through the validation of proposed framework in the process industry. Originality/value To the best of the authors’ knowledge, this study is first of its kind in this field of OHSMS in lean manufacturing organizations, especially the process industry. This study has involved both academicians and industry experts to bring more robust outcomes. This study proposed a unique framework to implement OHSMS in lean manufacturing organizations. This study has considered a comprehensive literature to develop a framework for OHSMS in lean manufacturing organizations. An implementation framework was proposed by considering both the academicians’ and industry professionals’ opinions. The proposed framework was statistically validated. This will be helpful in effective implementation of OHSMS strategy in lean manufacturing organizations, especially process industry sector.

Lean Manufacturing Practices and Integration of IR 4.0 Technologies for Sustainability in the Healthcare Manufacturing Industry

Providing affordable, safe, and reliable care while improving performance and efficiency remains a challenge in the healthcare sector. This study reviews the previous researches on the effect of lean manufacturing practice (LMP) and industrial revolution 4.0 technologies (IR 4.0 tech) on sustainability; however, there is still a paucity of literature on the implementation of the practices in the healthcare sector. Although studies have shown that LMP has significantly impacted organizational performance in the manufacturing industry, the integrated effects of LMP and IR 4.0 technologies on sustainable performance have not been empirically examined in the healthcare sector. This study, therefore, intends to have a preliminary conceptual approach to the joint effect of LPM and IR 4.0 technologies on sustainability before subsequently going for an empirical study to address the gap in the sector. The study aimed to confirm the future direction of the public health sector that has recently been employing new technologies in its service systems. The consequent study shall be based on data collected from the health practitioners who are working and familiar with the smart tools to expedite services for healthcare. However, this present study unfolds the significant contribution of operations management practices and how sustainable performance can be enhanced through performance variation and strategic implementation in the healthcare sector. Lean practices and IR 4.0 technologies lead to improvement and operational sustainability when fully implemented in the healthcare sector.