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1 – 10 of 110Norhana Mohd Aripin, Gusman Nawanir, Suhaidah Hussain and Taofeeq Durojaye Moshood
Lean manufacturing (LM) is a leading philosophy used by organizations to become inevitable in the challenging market. However, prior research showed evidence that 90% failure rate…
Abstract
Purpose
Lean manufacturing (LM) is a leading philosophy used by organizations to become inevitable in the challenging market. However, prior research showed evidence that 90% failure rate of LM within 10 years of implementation, hence this study is to undertake a systematic literature review on the failure of LM implementation.
Design/methodology/approach
This study was conducted with the guidance by review protocol, research questions’ formulation, systematic searching based on identification, screening and eligibility using Scopus and Web of Science databases, quality appraisal, data exclusion and analysis.
Findings
Derived from 15 sub-themes, five main themes were discovered based on the thematic analysis to answer the research question on “What strategies should manufacturers do to prevent the failure of LM implementation?”, namely (1) leadership, (2) culture, (3) knowledge, (4) resources and (5) suppliers.
Research limitations/implications
WoS and Scopus were employed in this review, despite there are 14 databases with the ability to search for potential articles in them. Mixed-Method Appraisal Tool (MMAT) was used to evaluate the quality control process, however using various quality assessment techniques helps to search for appropriate review objectives.
Practical implications
The primary emphasis of this study can be used as a reference by the manufacturers to ensure that LM implementation is a success story to gain a competitive advantage.
Originality/value
Despite a large body of literature on LM, there has been little attempt to review this study in a systematic approach, discover trends and generate thematic potential on the failure factors of LM, making it difficult for academics to replicate and interpret.
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Kristina M. Eriksson, Anna Karin Olsson and Linnéa Carlsson
Both technological and human-centric perspectives need to be acknowledged when combining lean production practices and Industry 4.0 (I4.0) technologies. This study aims to explore…
Abstract
Purpose
Both technological and human-centric perspectives need to be acknowledged when combining lean production practices and Industry 4.0 (I4.0) technologies. This study aims to explore and explain how lean production practices and I4.0 technologies may coexist to enhance the human-centric perspective of manufacturing operations in the era of Industry 5.0 (I5.0).
Design/methodology/approach
The research approach is an explorative and longitudinal case study. The qualitative data collection encompasses respondents from different job functions and organizational levels to cover the entire organization. In total, 18 interviews with 19 interviewees and five focus groups with a total of 25 participants are included.
Findings
Identified challenges bring forth that manufacturing organizations must have the ability to see beyond lean production philosophy and I4.0 to meet the demand for a human-centric perspective in socially sustainable manufacturing in the era of Industry 5.0.
Practical implications
The study suggests that while lean production practices and I4.0 practices may be considered separately, they need to be integrated as complementary approaches. This underscores the complexity of managing simultaneous organizational changes and new digital initiatives.
Social implications
The research presented illuminates the elusive phenomena comprising the combined aspects of a human-centric perspective, specifically bringing forth implications for the co-existence of lean production practices and I4.0 technologies, in the transformation towards I5.0.
Originality/value
The study contributes to new avenues of research within the field of socially sustainable manufacturing. The study provides an in-depth analysis of the human-centric perspective when transforming organizations towards Industry 5.0.
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Ebenezer Afum, Yaw Agyabeng-Mensah, Charles Baah and Essel Dacosta
This study aims to find out whether firms in the local textiles industry are benefiting from the combined implementation of lean practices (LPs) and quick-response manufacturing…
Abstract
Purpose
This study aims to find out whether firms in the local textiles industry are benefiting from the combined implementation of lean practices (LPs) and quick-response manufacturing (QRM) during the era of COVID-19. The study further explores the mediating role played by quick response manufacturing in the relationship between LPs, internal process performance (IPP) and customer performance.
Design/methodology/approach
A questionnaire is used to garner data from 123 local firms in Ghana’s textile industry. The analysis for all the hypothesized relationships is done using partial least square structural equation.
Findings
The results of the study indicate that LPs significantly strengthen the implementation of QRM. The result also suggests that LPs and QRM can be combined to influence IPP and customer performance. The results further suggest that QRM mediates the relationship between LPs, IPP and customer performance.
Originality/value
This study proposes and develops an integrated research model that explores the synergistic application of LPs and QRM in achieving improvements in IPP and customer performance from an emergent country perspective during the era of COVID-19. QRM serves as an important mechanism through which the relationship between LPs, IPP and customer performance can be explained.
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Andrei Bonamigo, Andrezza Nunes, Lucas Ferreira Mendes, Marcela Cohen Martelotte and Herlandí De Souza Andrade
This study aims to examine the impact of Lean 4.0 practices on value co-creation in the dairy ecosystem.
Abstract
Purpose
This study aims to examine the impact of Lean 4.0 practices on value co-creation in the dairy ecosystem.
Design/methodology/approach
Data collection were carried out through a questionary application with 126 professionals linked to the dairy ecosystem, including milk producers, milk cooperatives and milk transporters. The data were analyzed using Cluster Analysis, Mann-Whitney test and Chi-Square test.
Findings
A strong relation was found between the use of Lean 4.0 tools and the increase in operational performance, in addition to milk quality. Moreover, it can be noted that the use of digital technologies from Industry 4.0 has a strong relation with dairy production optimization, in other words, it is possible to be more efficient in the dairy process via Lean 4.0 adoption.
Research limitations/implications
The study is limited to analyzing the Brazilian dairy ecosystem. The results presented may not reflect the characteristics of the other countries.
Practical implications
Once the potential empirical impacts of the relation between Lean 4.0 and value co-creation are elucidated, it is possible to direct strategies for decision-making and guide efforts by researchers and professionals to deal with the waste mitigation present in the dairy sector.
Social implications
Lean 4.0 proves to be a potential solution to improve the operational performance of the dairy production system. Lean 4.0, linked to value co-creation, allows the integration of the production sector with consumers, through smart technologies, so new services and experiences can be provided to the consumer market. Additionally, the consumer experience can be stimulated based on Lean 4.0, once the quality specification is highlighted based on data science and smart management control.
Originality/value
To the best of the authors’ knowledge, this is the first study that analyzes the interrelationship between the Lean 4.0 philosophy and the value co-creation in the dairy ecosystem. In this sense, the study reveals the main contributions of this interrelation to the dairy sector via value co-creation, which demonstrates a new perspective on the complementarity of resources, elimination of process losses and new experiences for the user through digital technologies integrated with the Lean Thinking approach.
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Anand S. Patel and Kaushik M. Patel
India liberalized its economy in 1991, which resulted in intense global competition, quality-conscious and demanding customers. Additionally, significant technological…
Abstract
Purpose
India liberalized its economy in 1991, which resulted in intense global competition, quality-conscious and demanding customers. Additionally, significant technological advancements lead to enhancements in products and processes. These forced Indian organizations to adopt innovative business strategies in the past 30 years. Meanwhile, the Lean Six Sigma methodology has significantly grown with vast applicability during the past 30 years. Thus, the purpose of this study is to develop the learning on Lean Six Sigma methodology in the Indian context through investigation of literature.
Design/methodology/approach
A three-stage systematic literature review approach was adopted to investigate the literature during the present study. In total, 187 articles published in 62 journals/conference proceedings from 2005 to 2022 (18 years) were shortlisted. The first part of the article summarizes the significant milestones towards the quality journey in the Indian context, along with the evolution of the Lean Six Sigma methodology. The second part examines the shortlisted papers on Lean Six Sigma frameworks, their applicability in industrial sectors, performance metrics, outcomes realized, publication trends, authorship patterns and leading researchers from the Indian perspective.
Findings
Lean Six Sigma has emerged as a highly acclaimed and structured business improvement strategy worldwide. The Indian economy has seen remarkable growth in the past decade and is one of the fastest-growing economies in the 21st century. Lean Six Sigma implementation in India has significantly increased from 2014 onward. The study revealed that researchers have proposed several different frameworks for Lean Six Sigma implementation, the majority of which are conceptual. Furthermore, the balanced applicability of Lean Six Sigma in manufacturing and service sectors was observed with the highest implementation in the health-care sector. Additionally, the widely adopted tools, techniques along with performance metrics exploring case studies were reported along with a summary of eminent and leading researchers in the Indian context.
Research limitations/implications
This study is confined to reviewed papers as per the research criteria with a significant focus on the Indian context and might have missed some papers due to the adopted papers selection strategy.
Originality/value
The present study is one of the initial attempts to investigate the literature published on Lean Six Sigma in the Indian context, including perspective on the Indian quality movement. Therefore, the present study will provide an understanding of Lean Six Sigma methodology in the Indian context to graduating students in engineering and management and entry-level executives. The analysis and findings on Lean Six Sigma frameworks, research approach, publications details, etc., will be helpful to potential research scholars and academia. Additionally, analysis of case studies on Lean Six Sigma implementation by Indian industries will assist the managers and professionals in decision making.
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Kristen Snyder, Pernilla Ingelsson and Ingela Bäckström
This paper aims to explore how leaders can develop value-based leadership for sustainable quality development in Lean manufacturing.
Abstract
Purpose
This paper aims to explore how leaders can develop value-based leadership for sustainable quality development in Lean manufacturing.
Design/methodology/approach
A qualitative meta-analysis was conducted using data from a three-year study of Lean manufacturing in Sweden using the Shingo business excellence model as an analytical framework.
Findings
This study demonstrates that leaders can develop value-based leadership to support Lean manufacturing by defining and articulating the organization’s values and accompanying behaviors that are needed to support the strategic direction; creating forums and time for leaders to identify the why behind decisions and reflect on their experiences to be able to lead a transformative process; and using storytelling to create a coaching culture to connect values and behaviors, to the processes and systems of work.
Research limitations/implications
This paper contributes insights for developing value-based leadership to support a systemic approach to sustainable quality development in lean manufacturing. Findings are based on a limited case sample size of three manufacturing companies in Sweden.
Originality/value
The findings were derived using a unique methodological approach combining storytelling, appreciative inquiry and coaching with traditional data collection methods including surveys and interviews to identify, define and shape value-based leadership in Lean manufacturing.
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Mohammad Alnadi, Patrick McLaughlin and Ismail Abushaikha
This paper aims to identify leadership behaviours in the manufacturing sector in Jordan that enable successful Lean Six Sigma implementation.
Abstract
Purpose
This paper aims to identify leadership behaviours in the manufacturing sector in Jordan that enable successful Lean Six Sigma implementation.
Design/methodology/approach
Qualitative data were collected through 27 interviews to identify the leadership behaviours that facilitate Lean Six Sigma and a focus group to categorise the aspects by grouping them into themes. A grounded theory approach was used in the field study. The processes of constant comparisons helped in identifying the relevant aspects of leadership behaviours and integrating specific aspects into themes; these processes were iteratives. Therefore, this research project relies on the grounded theory methodology to collect and analyse the data. The authors also used a focus group to categorise the aspects by grouping them into themes. In that, the aspects were grouped around core categories.
Findings
After analysing the data, 36 aspects have emerged. The data analysis processes helped in discovering the aspects of leadership that support the use of Lean Six Sigma in the manufacturing sector in Jordan. The aspects were developed through an iterative process of analysis until the saturation level was reached. Eight themes that influence the successful use of Lean Six Sigma emerged: Training and development; Continuous improvement and development; Communication; Empowering employees; Motivating employees; Managing qualities and operations; Employees engagement and involvement; and Supporting culture
Research limitations/implications
There are some research limitations to this study, which opens avenues for future research. First, the data was collected through qualitative methods, which limits the generalizability of the results. Future studies are needed to generalize the results to the wider business community. Second, the data was collected only from manufacturing organizations and did not consider other sectors. Future researchers are urged to replicate the study in other sectors. Third, this study considered only Jordanian firms; therefore, the authors call upon further research to investigate other national settings that may have a different business culture.
Practical implications
This study encourages businesses to follow and adopt these behaviours in organisations, which can help in developing desirable behaviours among leaders to reach advanced levels in using Lean Six Sigma. Moreover, practitioners can develop training programmes for developing leaders. Thus, the Lean Six Sigma journey can become smoother by addressing the issues that face practitioners during the different phases of implementing Lean Six Sigma. In that respect, the practical implication of this research is to describe the practices that the leadership of organisations must develop to maintain high levels of Lean Six Sigma deployment.
Originality/value
Scholarly studies in this field are scarce, especially in developing countries, so identifying the leadership behaviours can help researchers create a theory of leadership behaviours for Lean Six Sigma. Furthermore, practitioners of Lean Six Sigma can take into account these behaviours as crucial to the effective use of Lean Six Sigma. They can encourage leaders to follow and adopt these behaviours in organisations which can help in developing desirable behaviours among leaders to reach advanced levels in using Lean Six Sigma. Thus, the Lean Six Sigma journey can become smoother by addressing the issues that practitioners face during the different phases of implementing Lean Six Sigma.
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Michelle Grace Tetteh-Caesar, Sumit Gupta, Konstantinos Salonitis and Sandeep Jagtap
The purpose of this systematic review is to critically analyze pharmaceutical industry case studies on the implementation of Lean 4.0 methodologies to synthesize key lessons…
Abstract
Purpose
The purpose of this systematic review is to critically analyze pharmaceutical industry case studies on the implementation of Lean 4.0 methodologies to synthesize key lessons, benefits and best practices. The goal is to inform decisions and guide investments in related technologies for enhancing quality, compliance, efficiency and responsiveness across production and supply chain processes.
Design/methodology/approach
The article utilized a systematic literature review (SLR) methodology following five phases: formulating research questions, locating relevant articles, selecting and evaluating articles, analyzing and synthesizing findings and reporting results. The SLR aimed to critically analyze pharmaceutical industry case studies on Lean 4.0 implementation to synthesize key lessons, benefits and best practices.
Findings
Key findings reveal recurrent efficiency gains, obstacles around legacy system integration and data governance as well as necessary operator training investments alongside technological upgrades. On average, quality assurance reliability improved by over 50%, while inventory waste declined by 57% based on quantified metrics across documented initiatives synthesizing robotics, sensors and analytics.
Research limitations/implications
As a comprehensive literature review, findings depend on available documented implementations within the search period rather than direct case evaluations. Reporting bias may also skew toward more successful accounts.
Practical implications
Synthesized implementation patterns, performance outcomes and concealed pitfalls provide pharmaceutical leaders with an evidence-based reference guide aiding adoption strategy development, resource planning and workforce transitioning crucial for Lean 4.0 assimilation.
Originality/value
This systematic assessment of pharmaceutical Lean 4.0 adoption offers an unprecedented perspective into the real-world issues, dependencies and modifications necessary for successful integration, absent from conceptual projections or isolated case studies alone until now.
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Taofeeq Durojaye Moshood, James O.B. Rotimi, Wajiha Shahzad and Maruf Gbadebo Salimon
Over the past two decades, the construction sector has experienced a surge in projects fueled by substantial government investment in infrastructure. However, amid this growth…
Abstract
Purpose
Over the past two decades, the construction sector has experienced a surge in projects fueled by substantial government investment in infrastructure. However, amid this growth, the industry grapples with persistent challenges. Meeting project deadlines and budgets remains a struggle, impacting the industry’s credibility. Therefore, this research intends to investigate the idea of lean construction in the construction sector and look at the obstacles facing the construction industry in implementing lean construction strategies.
Design/methodology/approach
The insights presented here result from content analysis performed on 206 articles, while the metadata analysis is based on 891 publications.
Findings
This study highlights numerous important characteristics that influence an organization’s capacity to accomplish lean construction using a systematic literature review approach.
Research limitations/implications
For forthcoming research seeking validation, utilizing a mixed-method approach could prove advantageous. Yet, it is crucial to recognize the constraints of the present study, primarily centered on the scope of the literature review.
Practical implications
This assessment will enhance comprehension of the lean construction concept, potentially encouraging the adopting of lean construction practices. Moreover, it could provide insights into effectively applying these methods in practice.
Originality/value
The literature review highlights the necessity for organizations to identify and address potential challenges they might encounter in implementing lean construction. An essential step in overcoming these obstacles involves exploring the concept of lean construction within the sector and assessing the hurdles constraining the implementation of lean construction strategies in the construction industry.
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Sheak Salman, Shah Murtoza Morshed, Md. Rezaul Karim, Rafat Rahman, Sadia Hasanat and Afia Ahsan
The 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…
Abstract
Purpose
The 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.
Findings
The 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/implications
The 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/value
This 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.
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