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Article
Publication date: 19 April 2013

Roberto Chavez, Cristina Gimenez, Brian Fynes, Frank Wiengarten and Wantao Yu

The purpose of this research is to examine the effect of internal lean practices on multiple operational performance dimensions, and assess the contingency perspective of these…

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Abstract

Purpose

The purpose of this research is to examine the effect of internal lean practices on multiple operational performance dimensions, and assess the contingency perspective of these relationships with respect to industry clockspeed.

Design/methodology/approach

The study is based on empirical data gathered from 228 manufacturing companies in the Republic of Ireland. The relationships between the constructs are analyzed through regression analysis.

Findings

The results indicate that the relationships between internal lean practices and quality, delivery, flexibility and cost were found to be positive and significant. Further, industry clockspeed was found to moderate the relationship between internal lean practices and quality, delivery and flexibility, but not cost.

Practical implications

While internal lean practices can improve operational performance, managers should be aware that internal lean practices are not universally applicable, and the rate of change within an industry should be considered at the time of implementing lean principles.

Originality/value

Much of the lean literature tends to be biased towards its effectiveness. However, empirical evidence shows that not all lean implementation have led to positive results, which has been attributed to the general complexity in the relationship between internal lean practices and performance. We propose to investigate further this relationship by disaggregating operational performance into four of its dimensions, namely quality, delivery, flexibility and cost, and by investigating the possible contingency effect of industry clockspeed.

Details

International Journal of Operations & Production Management, vol. 33 no. 5
Type: Research Article
ISSN: 0144-3577

Keywords

Article
Publication date: 27 July 2020

José Moyano-Fuentes, Juan Manuel Maqueira-Marín, Pedro José Martínez-Jurado and Macarena Sacristán-Díaz

The purpose of this paper is to investigate the contribution to improving the efficiency of the focal firm made by lean management at the internal and supply chain levels.

2210

Abstract

Purpose

The purpose of this paper is to investigate the contribution to improving the efficiency of the focal firm made by lean management at the internal and supply chain levels.

Design/methodology/approach

An empirical study was conducted of 285 Spanish focal companies from industrial sectors that occupy an intermediate position in the supply chain. The data gathering method consisted of a telephone survey using computer-assisted telephone interviewing. A structural equation was used to test the hypotheses.

Findings

The results indicate that there is an improvement in efficiency of the focal firm when lean management extends throughout the supply chain, in line with the resource-based theory and integrated supply chain management. In addition, lean management at the internal level is observed to impact positively on the focal firm's efficiency only when it contributes to enhancing the implementation of lean supply chain management.

Practical implications

To achieve the best operational performance derived from lean management, managers should pay attention to the transfer to their supply chain members of knowledge, competencies and cultural change linked to the level of internal lean implementation of the focal firm. Moreover, this paper provides a way to assess the operational aspects of lean supply chain strategy implementation and lean supply chain planning.

Originality/value

This study uses a holistic focus on lean supply chain management, to which it applies a validated instrument. It underlines that lean on the internal level should be complemented with lean on the supply chain level to provide a better understanding of the drivers of the efficiency of the focal firm.

Details

Journal of Manufacturing Technology Management, vol. 32 no. 1
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 16 December 2019

Léony Luis Lopes Negrão, Moacir Godinho Filho, Gilberto Miller Devós Ganga, Sunil Chopra, Matthias Thürer, Mário Sacomano Neto and Giuliano Almeida Marodin

The purpose of this paper is to explore the adoption of lean practices by manufacturing companies in regions of low economic and technological development and to compare findings…

Abstract

Purpose

The purpose of this paper is to explore the adoption of lean practices by manufacturing companies in regions of low economic and technological development and to compare findings with previous studies from more developed regions highlighting important contextual differences. The paper uses the contingency theory to explore how contextual variables and scarce resources influence the adoption of lean practices.

Design/methodology/approach

A survey of 233 manufacturing firms was conducted in the State of Pará in the Amazon Region of Brazil.

Findings

The results demonstrate that six internal lean practices (single minute exchange of dies, human resource management, continuous flow, total productive maintenance, pull and statistical process control) and two external lean practices (supplier feedback and customer involvement) are implemented. However, the two external lean practices of just-in-time delivery by suppliers and supplier development were not implemented. Furthermore, from the 36 operating items comprised in eight lean practices that are being used, 13 were not implemented. As such, compared to developed regions, there is evidence for a more fragmented implementation in less developed regions. The results reveal empirical evidence explained by the contingency perspective, such as national, geographical, strategic context and culture.

Originality/value

There is broad evidence on lean implementation in developed and developing countries in the literature. However, little is known about lean implementation in poorer regions of developing counties. This is one of the first studies mapping lean implementation in a region with low economic and technological development. This has important implications for research and practice, especially to cross-country/cultural research on operation management.

Details

Management Decision, vol. 58 no. 2
Type: Research Article
ISSN: 0025-1747

Keywords

Article
Publication date: 22 July 2020

Mohsin Malik and Salam Abdallah

Past studies of lean have failed to sufficiently address the importance of social factors for successful lean implementations. This paper aims to broaden and deepen the…

Abstract

Purpose

Past studies of lean have failed to sufficiently address the importance of social factors for successful lean implementations. This paper aims to broaden and deepen the understanding of lean as a socio-technical paradigm by conceptualizing lean implementation as an organizational change process.

Design/methodology/approach

This study draws on the organizational sense-making literature to conceptualize and validate lean implementation as an organizational change process that necessitates a focus on the ability of organizational actors to construct a shared meaning of lean. This study posit that this shared understanding shapes the collective behaviour and attitudes of people towards a future desired organizational state such as a successful implementation of lean. Survey data were collected from various manufacturing and services firms to test the hypothesis derived from literature using a structural equation modelling approach.

Findings

The mutual social interactions of organizational actors contribute to an enabling lean organizational attitude that has a dominant effect on the lean practices of employee involvement, internal technical practices, supplier and customer management. This study also established boundary conditions for these relationships by identifying firm size as a moderating variable.

Research limitations/implications

The findings establish a supportive organizational attitude as an antecedent for lean implementation, which goes beyond the current socio-technical characterization of lean management. This conceptualization draws the attention of researchers and practitioners towards the critical role of the cooperative behaviours of organizational actors in lean implementations.

Originality/value

The statistical results add a novel perspective to the discourse on the social dimension of lean implementation by conceptualizing and validating lean management as a combination of organizational attitude and the process facilitators comprising of employee empowerment, internal technical practices, supplier and customer management.

Details

Industrial Management & Data Systems, vol. 120 no. 9
Type: Research Article
ISSN: 0263-5577

Keywords

Article
Publication date: 18 December 2020

Protik Basu, Debaleena Chatterjee, Indranil Ghosh and Pranab K. Dan

The purpose of this study is to explore the mediation effect of volatile economic conditions on performance benefits of successful kean manufacturing implementation (LMI). The…

Abstract

Purpose

The purpose of this study is to explore the mediation effect of volatile economic conditions on performance benefits of successful kean manufacturing implementation (LMI). The mediating factor of economic volatility (EV) is constructed based on four macroeconomic dimensions – supplier uncertainty, market demand fluctuations, governmental policy changes and peer competition.

Design/methodology/approach

An attempt is made to build an exhaustive list of the internal operational manifests grouped into one human and three technical input factors. Similarly the benefits accrued are collated under two performance measures – customer satisfaction (CS) and organizational goal satisfaction (OGS). Based on data from the Indian manufacturing sector, structural equation modelling (SEM) and ordinary least square (OLS) analyses are carried out to validate the proposed model.

Findings

Results of the structural model validate the first six hypotheses posited in the model. Results of OLS further reveal the mediation effect of EV having negative impact on LMI–CS and LMI–OGS nexus.

Practical implications

This research offers a fair understanding of the internal operational lean factors and the effect of volatile macroeconomic conditions on lean benefits. The structural model will aid the academicians and lean implementers comprehend the dimensional structure underlying the lean practices and beliefs. This work further helps to understand the moderation effect of environmental complexity on the output measures of LMI in the Indian manufacturing sector.

Originality/value

This work is one of the very first empirical analyses of lean performance under contingent economic conditions. The paper presents a valuable recommendation to practitioners for considering the dynamism of external economic environment instead of simply adopting standalone internal lean parameters, if satisfactory levels of performance in terms of CS and OGS are to be achieved.

Details

Journal of Manufacturing Technology Management, vol. 32 no. 6
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 3 April 2024

Chao-chao Liu, Miao Wang, Zhanwen Niu and Xun Mo

The view that dynamic capabilities theory can help explain how lean organizations improve has been put forward by scholars. However, there is still a lack of research on the…

Abstract

Purpose

The view that dynamic capabilities theory can help explain how lean organizations improve has been put forward by scholars. However, there is still a lack of research on the matching relationship between the application of lean practice and the internal elements of enterprise organization from the perspective of dynamic capabilities. The purpose of this study is to validate the moderating effect of dynamic capabilities on the relationship between lean practices and operational performance.

Design/methodology/approach

This study used the method of survey and empirical research to collect sample data from 263 enterprises in China. Through literature review, this study put forward the moderating hypotheses around dynamic capabilities, lean practices and operation performance and used the method of regression analysis to validate these hypotheses.

Findings

The results showed that dynamic capabilities have a partially moderating effect on the application of lean practices. Specifically, dynamic capabilities have a significant moderating effect on the relationship between just-in-time, total quality management, total preventive maintenance and operational performance, while dynamic capabilities have no significant moderating effect on the relationship between human resource management and operational performance.

Originality/value

The research conclusion complements and enriches the lean practices literature from the perspective of dynamic capabilities. Existing studies mainly focus on the moderating role of external environmental factors, while there is a lack of empirical research on the role of dynamic capabilities in lean practices literature. The research results will help enterprises further understand the matching relationship between lean practices and dynamic capabilities and then improve the success of lean practices application.

Details

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

Keywords

Article
Publication date: 19 May 2022

Atul Kumar Sahu, Mahak Sharma, Rakesh D. Raut, Anoop Kumar Sahu, Nitin Kumar Sahu, Jiju Antony and Guilherme Luz Tortorella

Today, proficient practices are required to stimulate along various boundaries of the supply chain (SC) to exploit manufacturing resources economically, effectually and gracefully…

1171

Abstract

Purpose

Today, proficient practices are required to stimulate along various boundaries of the supply chain (SC) to exploit manufacturing resources economically, effectually and gracefully for retaining operational excellence. Accordingly, varieties of paramount practices, i.e. Lean, Agile, Resilient and Green practices, are integrated in present study with the objective to develop a Decision Support Framework (DSF) to select robust supplier under the extent of Lean-Agile-Resilient-Green (LARG) practices for a manufacturing firm. The framework is developed and validated in the Indian automotive sector, where the primary data is collected based on perceptions of the respondents working in an automotive company.

Design/methodology/approach

LARG metrics can ponder ecological balance, customer satisfaction, associations, effectiveness and sustainability and thus, the study consolidated LARG practices in one umbrella to develop a DSF. The analytical approach under DSF is developed by the integration AHP, DEMATEL, ANP, Extended MOORA and SAW techniques in present study to evaluate a robust supplier under the aegis of LARG practices in SC. DSF is developed by scrutinizing and categorizing LARG characteristics, where the selected LARG characteristics are handled by fuzzy sets theory to deal with the impreciseness and uncertainty in decision making.

Findings

The study has identified 63 measures (15 for Lean, 15 for Agile, 14 for resilient and 19 for Green) to support the robust supplier selection process for manufacturing firms. The findings of study explicate “Internal communication agility”, “Interchangeability to personnel resources”, “Manufacturing flexibility”, “degree of online solution”, “Quickness to resource up-gradation”, “Manageability to demand and supply change”, “Overstocking inventory practices” as significant metrics in ranking order. Additionally, “Transparency to share information”, “Internal communication agility”, “Manufacturing Flexibility”, “Green product (outgoing)” are found as influential metrics under LARG practices respectively.

Practical implications

A technical DSF to utilize by the managers is developed, which is connected with knowledge-based theory and a case of an automobile manufacturing firm is presented to illustrate its implementation. The companies can utilize presented DSF to impose service excellence, societal performance, agility and green surroundings in SC for achieving sustainable outcomes to be welcomed by the legislations, society and rivals. The framework represents an important decision support tool to enable managers to overcome imprecise SC information sources.

Originality/value

The study presented a proficient platform to review the most significant LARG alternative in the SC. The study suggested a cluster of LARG metrics to support operational improvement in manufacturing firms for shifting gear toward sustainable SC practices. The present study embraces its existence in enrolling a high extent of collaboration amongst clients, project teams and LARG practices to virtually eradicate the likelihood of absolute project failure.

Open Access
Article
Publication date: 22 November 2022

Leopoldo Gutierrez, Bart Alex Lameijer, Gopesh Anand, Jiju Antony and Vijaya Sunder M

The purpose of this study is to theorize and test the relationships among lean operations and lean supply chain practices, learning- and innovation-oriented lean cultures and…

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Abstract

Purpose

The purpose of this study is to theorize and test the relationships among lean operations and lean supply chain practices, learning- and innovation-oriented lean cultures and dynamic capabilities (DCs) microfoundations. Further, this study aims to assess the association of DCs microfoundations with process innovation.

Design/methodology/approach

The researchers combine primary data collected from 153 manufacturing firms located in five continents using a survey designed for the purpose of this study with archival data downloaded from the Bureau Van Dijk Orbis database and test the hypothesized relationships using structural equation modelling.

Findings

Results support the contribution of lean operations and lean supply chain practices to the development of DCs microfoundations, which further lead to greater process innovation. Additionally, while a learning-oriented lean culture positively moderates the relationships between both lean operations and lean supply chain practices and DCs microfoundations, an innovation-oriented lean culture only moderates the relationship between lean operations practices and DCs microfoundations.

Practical implications

This study identifies DCs microfoundations as the key mechanisms for firms implementing lean practices to achieve greater levels of process innovation and the important role played by lean cultures. This study provides direction for managers to put in place DCs through lean implementations, enabling their firms to be ready to respond to challenges and opportunities generated by environmental changes.

Originality/value

While previous research has confirmed the positive effects of lean practices on efficiency, the role of lean practices and cultures in developing capabilities for reacting to environmental dynamism has received little attention. This study offers an empirically supported framework that highlights the potential of lean to adapt processes in response to environmental dynamics, thereby extending the lean paradigm beyond the traditional focus on operational efficiency.

Details

International Journal of Operations & Production Management, vol. 42 no. 13
Type: Research Article
ISSN: 0144-3577

Keywords

Article
Publication date: 16 August 2011

Adriana Rossiter Hofer, Christian Hofer, Cuneyt Eroglu and Matthew A. Waller

The purpose of this paper is to assess the current state of implementation of lean production practices in China as compared to the USA. Moreover, an institutional‐theoretic…

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Abstract

Purpose

The purpose of this paper is to assess the current state of implementation of lean production practices in China as compared to the USA. Moreover, an institutional‐theoretic framework is developed that explores the interplay among economic, socio‐cultural and regulative forces that may shape the adoption process of lean production practices in China.

Design/methodology/approach

The paper draws its conclusions from an analysis of survey data from samples of Chinese and US manufacturing executives. Lean production implementation is measured via a survey instrument, and the data are analyzed via regression analysis.

Findings

The results suggest that the degree of implementation of lean production in China is equal to, if not greater than lean production implementation in the USA. While the results are fairly consistent across industries, they vary across different lean production practice bundles. In light of these findings, an institutional theory perspective is adopted to develop further insight into the potential drivers of and barriers to lean production implementation in China. It is argued that, while several economic factors function as enablers for the implementation of these practices, various social processes and cultural traits in China still hinder the full adoption of lean production.

Research limitations/implications

Larger‐scale empirical studies are required for further hypothesis testing and enhanced validity. In particular, the explicit measurement of institutional forces and the statistical analysis of their effects on lean production adoption are recommended for future research.

Originality/value

This is the first study to systematically compare the adoption of lean practices in China and the USA. The analyses and discussions provide a basis for further theory building and hypothesis testing research. In addition, the insights offered in this study may help firms gain a better understanding of the unique opportunities and challenges associated with adoption of lean production in China.

Details

The International Journal of Logistics Management, vol. 22 no. 2
Type: Research Article
ISSN: 0957-4093

Keywords

Article
Publication date: 8 March 2024

Roberto Chavez, Wantao Yu, Mark Jacobs and Chee Yew Wong

This study aims to investigate whether Industry 4.0 digital technologies can enhance the effects of lean production on social performance.

Abstract

Purpose

This study aims to investigate whether Industry 4.0 digital technologies can enhance the effects of lean production on social performance.

Design/methodology/approach

Survey data collected from China’s manufacturing industry are used to test research hypotheses.

Findings

The results reveal that the three dimensions of lean production (internal, customer and supplier) have a significant positive effect on social performance and that digital technology advancement (DTA) positively moderates these relationships. DTA adds only a marginal contribution to social performance.

Practical implications

This study addresses a new challenging question from manufacturing firms: how to integrate lean, technology and people? The empirical findings provide timely and insightful practical guidance for managers to better understand the role of digital transformation in the traditional lean context.

Originality/value

While digitalization is known to complement lean production, this study shows digitalization also complements the effects of lean production on social performance.

Details

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

Keywords

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