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Article
Publication date: 29 May 2024

Haftu Hailu Berhe, Hailekiros Sibhato Gebremichael, Kinfe Tsegay Beyene and Haileselassie Mehari Gebremedhin

Continuous improvement in an integrated approach is a philosophy developed over decades based on a set of management practices. It comprises enhancement methodologies that…

Abstract

Purpose

Continuous improvement in an integrated approach is a philosophy developed over decades based on a set of management practices. It comprises enhancement methodologies that escalate success as well as diminishes letdowns. The state-of-the-art literature finds a variety of practices for the execution of continuous improvement (CI) system. However, it is rare to find an empirical study with an inclusive system that considers various practices in one frame for improving competitiveness. With this outlook, therefore, this study aims originally to identify drivers, motivations and barriers for the application of integrated CI system, and then conduct an empirical investigation within the context of Ethiopian manufacturing industries.

Design/methodology/approach

Justification of the problem, extensive review of literature, identification of practices, developing research framework, investigational analysis of the empirical study using reliability and descriptive statistical analysis and identifying leading drivers (unique practices and common factors), motivations and barriers are the research approaches used in this study. Furthermore, the primary data were collected through a self-administered questionnaire and were analyzed using a statistical package for social science (SPSS) 23 and the findings were triangulated to relate to the existing state-of-the-art literature.

Findings

The findings indicate 17 common factors associated with human, strategic, operational, technology, structure, resource and information factors; 21 unique practices of just-in-time (JIT), lean-six sigma (LSS), supply chain management (SCM), total productive maintenance (TPM), and total quality management (TQM) methodologies; 20 barriers connected with internal and external issues and 17 motivations linked to operational, innovation and business results are identified. In general, the empirical analysis discovers the practices are noteworthy and commonly supported by a least of 52% of the respondents. As a result, the first five prominent common factors, barriers, unique practices and motivations are also supported by a minimum of 72%, 73.9%, 65.8% and 75% of the respondents, respectively.

Research limitations/implications

Even though this is the first-ever study in the Ethiopian manufacturing sector with the focus on integrated CI practices of JIT, TQM, TPM, SCM and LSS initiatives, some limitations have existed and the major limitations of the study are, targeted merely small number manufacturing companies despite the fact that there are hundreds of companies implementing CI system in Ethiopia, and the data collected were only based on the perception of the respondents, and other information’s like annual reports was not employed to support the findings.

Practical implications

The findings of this study underlined that the implementation of drivers in relation to common factors and unique practices supported by exterminating barriers in manufacturing industries of Ethiopia enables to enhance competitiveness through attaining operational, innovation and business results though it requires a practical case application to prove this perception-based analysis.

Originality/value

Though there are a number of studies published on integrated continuous improvement, currently it is found that there is no literature focused on the identification and empirical investigation of drivers (common factors and unique practices), motivations and barriers for application of integrated CI system with the focus of JIT, TQM, TPM, SCM and LSS initiatives. Therefore, this is the first-ever study, and the empirical analysis of the study discovered that identified practices are providing valuable insights for manufacturing industries which will be on board on this voyage including institutions, practitioners and other sectors.

Details

International Journal of Quality & Reliability Management, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 0265-671X

Keywords

Article
Publication date: 25 October 2022

Ashkan Memari, Hamid Reza Panjehfouladgaran, Abd. Rahman Abdul Rahim and Robiah Ahmad

This paper aims to investigate the impact of adopting lean manufacturing principles on operational efficiency by eliminating seven major lean wastes (or Muda) in a Malaysian…

Abstract

Purpose

This paper aims to investigate the impact of adopting lean manufacturing principles on operational efficiency by eliminating seven major lean wastes (or Muda) in a Malaysian stationery manufacturer. Much of the research on lean considers its application to larger organisations with stable demand patterns. This research examines a small- and medium-sized enterprise (SME) with a volatile demand pattern.

Design/methodology/approach

A process activity mapping (PAM) methodology was utilized to identify the potential for waste elimination. PAM is a visual tool that considers every step in a production process. Value-added and non-value-added activities are therefore examined to understand hidden wastes and their sources.

Findings

The results revealed that the adopted lean principles significantly reduce the waiting times. This time reduction resulted in savings (reduction of cycle time) and to a certain extent, can be a crucial driver in continuous improvement sustainability in the production process.

Research limitations/implications

The study focuses on a single case study and provides a springboard for further research. Future studies examining the results across a broader sample of organisations would develop the findings further.

Practical implications

The extant literature cites mixed success for lean implementation programmes. The results demonstrate that lean is still recognised as a powerful approach to improving operations in SMEs.

Originality/value

This paper reflects on the application of lean in a real case study showing the impact of lean on operational performance of an SME.

Details

Asia-Pacific Journal of Business Administration, vol. 16 no. 3
Type: Research Article
ISSN: 1757-4323

Keywords

Open Access
Article
Publication date: 12 May 2023

Olivia McDermott, Kevin ODwyer, John Noonan, Anna Trubetskaya and Angelo Rosa

This study aims to improve a construction company's overall project delivery by utilising lean six sigma (LSS) methods combined with building information modelling (BIM) to…

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Abstract

Purpose

This study aims to improve a construction company's overall project delivery by utilising lean six sigma (LSS) methods combined with building information modelling (BIM) to design, modularise and manufacture various building elements in a controlled factory environment off-site.

Design/methodology/approach

A case study in a construction company utilised lean six sigma (LSS) methodology and BIM to identify non-value add waste in the construction process and improve sustainability.

Findings

An Irish-based construction company manufacturing modular pipe racks for the pharmaceutical industry utilised LSS to optimise and standardise their off-site manufacturing (OSM) partners process and leverage BIM to design skids which could be manufactured offsite and transported easily with minimal on-site installation and rework required. Productivity was improved, waste was reduced, less energy was consumed, defects were reduced and the project schedule for completion was reduced.

Research limitations/implications

The case study was carried out on one construction company and one construction product type. Further case studies would ensure more generalisability. However, the implementation was tested on a modular construction company, and the methods used indicate that the generic framework could be applied and customized to any offsite company.

Originality/value

This is one of the few studies on implementing offsite manufacturing (OSM) utilising LSS and BIM in an Irish construction company. The detailed quantitative benefits and cost savings calculations presented as well as the use of the LSM methods and BIM in designing an OSM process can be leveraged by other construction organisations to understand the benefits of OSM. This study can help demonstrate how LSS and BIM can aid the construction industry to be more environmentally friendly.

Details

International Journal of Lean Six Sigma, vol. 15 no. 8
Type: Research Article
ISSN: 2040-4166

Keywords

Open Access
Article
Publication date: 22 March 2024

Ambra Galeazzo, Andrea Furlan, Diletta Tosetto and Andrea Vinelli

We studied the relationship between job engagement and systematic problem solving (SPS) among shop-floor employees and how lean production (LP) and Internet of Things (IoT…

Abstract

Purpose

We studied the relationship between job engagement and systematic problem solving (SPS) among shop-floor employees and how lean production (LP) and Internet of Things (IoT) systems moderate this relationship.

Design/methodology/approach

We collected data from a sample of 440 shop floor workers in 101 manufacturing work units across 33 plants. Because our data is nested, we employed a series of multilevel regression models to test the hypotheses. The application of IoT systems within work units was evaluated by our research team through direct observations from on-site visits.

Findings

Our findings indicate a positive association between job engagement and SPS. Additionally, we found that the adoption of lean bundles positively moderates this relationship, while, surprisingly, the adoption of IoT systems negatively moderates this relationship. Interestingly, we found that, when the adoption of IoT systems is complemented by a lean management system, workers tend to experience a higher effect on the SPS of their engagement.

Research limitations/implications

One limitation of this research is the reliance on the self-reported data collected from both workers (job engagement, SPS and control variables) and supervisors (lean bundles). Furthermore, our study was conducted in a specific country, Italy, which might have limitations on the generalizability of the results since cross-cultural differences in job engagement and SPS have been documented.

Practical implications

Our findings highlight that employees’ strong engagement in SPS behaviors is shaped by the managerial and technological systems implemented on the shop floor. Specifically, we point out that implementing IoT systems without the appropriate managerial practices can pose challenges to fostering employee engagement and SPS.

Originality/value

This paper provides new insights on how lean and new technologies contribute to the development of learning-to-learn capabilities at the individual level by empirically analyzing the moderating effects of IoT systems and LP on the relationship between job engagement and SPS.

Details

International Journal of Operations & Production Management, vol. 44 no. 6
Type: Research Article
ISSN: 0144-3577

Keywords

Article
Publication date: 6 September 2022

Choon Ling Sim, Francis Chuah, Kit Yeng Sin and Yi Jin Lim

The purpose of this paper is to explore the moderating role of Lean Six Sigma (LSS) practices in explaining the relationship between quality management practices (QMPs) and…

Abstract

Purpose

The purpose of this paper is to explore the moderating role of Lean Six Sigma (LSS) practices in explaining the relationship between quality management practices (QMPs) and quality performance.

Design/methodology/approach

Partial least square-based structural equation modeling (PLS-SEM) was used to empirically examine the moderating effect of LSS practices on QMPs and quality performance in Malaysian medical device manufacturing companies.

Findings

Findings revealed that both QMPs and LSS practices have a significant and positive effect on quality performance. Furthermore, LSS practices served as a substitute for moderating the positive relationship between QMPs and quality performance in such a way that the relationship becomes weaker as LSS practices increase.

Originality/value

LSS is acknowledged as the most well-known hybrid methodology; however, due to its relative newness, it has not been studied in great detail. Unlike previous studies, this paper argued that Lean and Six Sigma practices are distinct from its predecessor TQM practices; moreover, both Lean and Six Sigma practices do not need to substitute QM/TQM practices instead of complimenting the QMPs. In addition, this study adds to the growing body of QM literature by empirically examine the effect of LSS practices in moderating the relationship between QMPs and quality performance.

Details

The TQM Journal, vol. 36 no. 5
Type: Research Article
ISSN: 1754-2731

Keywords

Book part
Publication date: 21 May 2024

Muhammad Shujaat Mubarik and Sharfuddin Ahmed Khan

Digital technologies (DTs) have emerged as a major driving force, transmuting the ways Supply Chains (SCs) are managed. The integration of DTs in supply chain management (SCM)…

Abstract

Digital technologies (DTs) have emerged as a major driving force, transmuting the ways Supply Chains (SCs) are managed. The integration of DTs in supply chain management (SCM), Digital Supply Chain Management (DSCM), has fundamentally reshaped the SCM landscape, offering new opportunities and challenges for organizations. This chapter provides a comprehensive overview of modern DTs and the way they impact modern SCM. This chapter has twofold objectives. First, it illustrates the major changes that DTs have brought to the supply chain landscape, unraveling their multifaceted implications. Second, it offers readers a deeper and comprehensive understanding of the challenges and opportunities arising from the incorporation of DTs into supply chains. By going through the chapter, readers will be able to have a comprehensive grasp of how DTs are reshaping SCM and how organizations can survive and thrive in the digital age. This chapter commences by shedding light on how DTs have and continue to redefine SCM, improving supply chain resilience, visibility, and sustainability in an increasingly complex and interconnected world. It also highlights the role of DTs in enhancing SC visibility, agility, and customer-centricity. Furthermore, this chapter briefly highlights the challenges related to the adoption (pre and post) of DTs in SCM, elucidating on issues related to talent acquisition, data security, and regulatory compliance. It also highlights the ethical and societal implications of this digital transformation, emphasizing the significance of responsible and sustainable practices. This chapter, with the help of three cases, illustrates how the adoption of DTs in SC can impact the various SC performance indicators.

Details

The Theory, Methods and Application of Managing Digital Supply Chains
Type: Book
ISBN: 978-1-80455-968-0

Keywords

Open Access
Article
Publication date: 24 January 2024

Jasmine Elizabeth Black, Damian Maye, Anna Krzywoszynska and Stephen Jones

This paper examines how key actors in the UK food system (FS) understand the role of the local food sector in relation to FS resilience.

Abstract

Purpose

This paper examines how key actors in the UK food system (FS) understand the role of the local food sector in relation to FS resilience.

Design/methodology/approach

Discourse analysis was used to assess and compare the framings of the UK FS in 36 publications released during Covid-19 from alternative food networks (AFNs) actors and from other more mainstream FS actors, including the UK government.

Findings

The analysis shows that AFNs actors perceive the UK FS as not resilient and identify local FSs as a route towards greater resilience (“systemic” framing). In contrast, other food actors perceive the UK FS as already resilient, with the role of local food limited to specific functions within the existing system (“add-on” framing). The two groups converge on the importance of dynamic public procurement and local abattoir provision, but this convergence does not undermine the fundamental divergence in the understanding of the role of “the local” in resilient UK FSs. The local food sector’s messages appear to have gone largely unheard in mainstream policy.

Research limitations/implications

The paper presents an analysis of public sector reports focused on the UK FS released during the Covid-19 pandemic years 2020–2021. The corpus inclusion criteria mean that publications during this period which focus on other food sector issues, such social injustices, climate change and health, were not included in the analysis, although they may have touched upon local food issues. The authors further recognise that Covid-19 had a longer lasting effect on FSs than the years 2020–2021, and that many other publications on FSs have been published since. The time span chosen targets the time at which FSs were most disrupted and therefore aims to capture emerging issues and solutions for the UK FS. The authors’ insights should be further validated through a more complete review of both public reports and academic papers covering a wider base of food-related issues and sectors as well as a broader timespan.

Originality/value

A comparison of how different FS actors understand the importance of local food, especially in relation to resilience, has not been undertaken to date. The findings raise important questions about the disconnect between AFN actors and other actors in the framing of resilience. Considering the need to ensure resilience of the UK FS, this study's findings raise important insights for UK food policy about the “local food blindspot” and for food movement actors wishing to progress their vision of transformative change.

Details

British Food Journal, vol. 126 no. 13
Type: Research Article
ISSN: 0007-070X

Keywords

Book part
Publication date: 21 May 2024

Muhammad Shujaat Mubarik and Sharfuddin Ahmed Khan

The supply chain is undergoing a significant digital transformation to adapt to the increasingly digitalized and globalized business environment. To remain competitive in this…

Abstract

The supply chain is undergoing a significant digital transformation to adapt to the increasingly digitalized and globalized business environment. To remain competitive in this evolving market, businesses must seamlessly integrate digital technologies throughout the supply chain, spanning all stages from procurement to distribution. This chapter delves into models and methodologies critical to digital supply chain (DSC) transformation, with a focus on advanced techniques such as the Internet of Things (IoT), artificial intelligence (AI), blockchain, and data analytics to boost the resilience and agility of supply chain operations. By leveraging practical examples and case studies, the chapter highlights the myriad enhancements digital transformation can introduce across diverse supply chain stages, including sourcing and after-sales service. Additionally, the chapter examines the complexities of cybersecurity, data integrity, and change management within the digital transformation framework, proposing strategies to address these challenges. The insights offered in this chapter will serve as a thorough guide for both practitioners and scholars in the supply chain field, equipping them to adeptly navigate the multifaceted arena of digital transformation.

Details

The Theory, Methods and Application of Managing Digital Supply Chains
Type: Book
ISBN: 978-1-80455-968-0

Keywords

Open Access
Article
Publication date: 9 April 2024

Krisztina Demeter, Levente Szász, Béla-Gergely Rácz and Lehel-Zoltán Györfy

The purpose of this paper is to investigate how different manufacturing technologies are bundled together and how these bundles influence operations performance and, indirectly…

Abstract

Purpose

The purpose of this paper is to investigate how different manufacturing technologies are bundled together and how these bundles influence operations performance and, indirectly, business performance. With the emergence of Industry 4.0 (I4.0) technologies, manufacturing companies can use a wide variety of advanced manufacturing technologies (AMT) to build an efficient and effective production system. Nevertheless, the literature offers little guidance on how these technologies, including novel I4.0 technologies, should be combined in practice and how these combinations might have a different impact on performance.

Design/methodology/approach

Using a survey study of 165 manufacturing plants from 11 different countries, we use factor analysis to empirically derive three distinct manufacturing technology bundles and structural equation modeling to quantify their relationship with operations and business performance.

Findings

Our findings support an evolutionary rather than a revolutionary perspective. I4.0 technologies build on traditional manufacturing technologies and do not constitute a separate direction that would point towards a fundamental digital transformation of companies within our sample. Performance effects are rather weak: out of the three technology bundles identified, only “automation and robotization” have a positive influence on cost efficiency, while “base technologies” and “data-enabled technologies” do not offer a competitive advantage, neither in terms of cost nor in terms of differentiation. Furthermore, while the business performance impact is positive, it is quite weak, suggesting that financial returns on technology investments might require longer time periods.

Originality/value

Relying on a complementarity approach, our research offers a novel perspective on technology implementation in the I4.0 era by investigating novel and traditional manufacturing technologies together.

Details

Journal of Manufacturing Technology Management, vol. 35 no. 9
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 28 May 2024

Graziela dos Santos Bento and Gérson Tontini

Based 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…

Abstract

Purpose

Based 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/approach

Employee 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.

Findings

The 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 implications

This 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/value

Previous 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.

Details

International Journal of Lean Six Sigma, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 2040-4166

Keywords

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