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Development of lean and sustainability practices assessment method among shop floor workers in manufacturing operation: a case study

Kasturi Muniapan (Faculty of Mechanical Engineering Technology, Universiti Malaysia Perlis, Arau, Malaysia)
Rosmaini Ahmad (Faculty of Mechanical Engineering Technology (Manufacturing Engineering), Universiti Malaysia Perlis, Arau, Malaysia)
Muhammad Shahar Jusoh (Faculty of Applied and Human Sciences, Universiti Malaysia Perlis, Arau, Malaysia)
Shaliza Azreen Mustafa (Faculty of Mechanical Engineering Technology (Manufacturing Engineering), Universiti Malaysia Perlis, Arau, Malaysia)
Tan Chan Sin (Faculty of Mechanical Engineering Technology (Manufacturing Engineering), Universiti Malaysia Perlis, Arau, Malaysia)

International Journal of Productivity and Performance Management

ISSN: 1741-0401

Article publication date: 29 November 2024

49

Abstract

Purpose

This paper proposes an assessment method for lean and sustainability (LS) practices for shop-floor workers, designed to evaluate their current practice culture.

Design/methodology/approach

The method is developed in five phases: setting predefined indicators, constructing the assessment mechanism, implementing the assessment procedure, analyzing data and delivering results with recommendations. Validation is performed using two worker groups – line supervisors and operators – within the light-emitting diode (LED) manufacturing industry.

Findings

The results showed that workers’ familiarity and understanding of LS practices do not always correspond to their awareness levels. Key recommendations include prioritizing training for critical cases and adapting training approaches to fit the specific knowledge profiles identified.

Research limitations/implications

Firstly, the company should integrate the proposed assessment into an online platform that can automatically generate individual statistical results and priority levels. This reduces the burden of manual work and makes large-scale assessments more practical. Secondly, the study should expand to other shop-floor workers, such as technicians and engineers, to assess their knowledge profiles for future LS development initiatives.

Practical implications

The recommendations provide managers and training departments with guidelines to revise current training approaches. The methodology is validated, enabling the identification and mapping of each worker’s knowledge profile.

Originality/value

This study presents an original assessment method for evaluating the knowledge profiles of shop-floor workers regarding LS practices. To the best of the authors’ knowledge, no prior literature has reported on an assessment method targeting this specific group. The proposed approach supports the decision-making process for better LS practices in the company.

Keywords

Acknowledgements

The authors wish to acknowledge the assistance and support from colleagues, top management, and technical staff at the case study company, especially in providing data and related project information. The authors also thank the referees for their useful suggestions.

Citation

Muniapan, K., Ahmad, R., Jusoh, M.S., Mustafa, S.A. and Sin, T.C. (2024), "Development of lean and sustainability practices assessment method among shop floor workers in manufacturing operation: a case study", International Journal of Productivity and Performance Management, Vol. ahead-of-print No. ahead-of-print. https://doi.org/10.1108/IJPPM-02-2024-0084

Publisher

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Emerald Publishing Limited

Copyright © 2024, Emerald Publishing Limited

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