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Article
Publication date: 20 May 2024

Norhana 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.

Details

Technological Sustainability, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 2754-1312

Keywords

Open Access
Article
Publication date: 12 April 2024

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.

Details

Technological Sustainability, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 2754-1312

Keywords

Article
Publication date: 16 February 2024

Agana Parameswaran, K.A.T.O. Ranadewa and Akila Pramodh Rathnasinghe

The proliferation of lean principles in the construction industry is offset by the enduring uncertainty among industry stakeholders regarding their respective roles in lean…

Abstract

Purpose

The proliferation of lean principles in the construction industry is offset by the enduring uncertainty among industry stakeholders regarding their respective roles in lean implementation. This uncertainty is further compounded by the scarcity of empirical investigations in this area. Consequently, this study undertakes the task of bridging this knowledge gap by identifying the critical roles of lean learners and their indispensable contributions to achieving successful lean implementation.

Design/methodology/approach

A qualitative exploratory approach informed by an interpretivism perspective was adopted. The case study strategy was employed to gather data from three contracting organisations that had implemented lean practices. Empirical data was collected through in-depth semi-structured interviews with fifteen industry experts and complemented by document reviews. To analyse the data, a code-based content analysis approach was employed using NVivo software, while Power BI software was utilised to develop a comprehensive force-directed graph visualisation.

Findings

The research findings substantiated nine lean learners and unveiled a set of seventy-three roles associated with them. The force-directed graph facilitated the identification of lean learners and their connections to the emerged roles. Notably, the graph highlighted the pivotal role played by project managers and internal lean trainers in ensuring the success of lean implementation, surpassing the contributions of other lean learners.

Originality/value

The implications of findings extend to industry professionals seeking to establish a robust lean learning framework to expedite lean implementation within the construction sector. This study not only provides a comprehensive definition of lean learners’ roles but also transcends specific construction types, making it a significant catalyst for global impact.

Details

International Journal of Productivity and Performance Management, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1741-0401

Keywords

Article
Publication date: 28 February 2024

Anupama Prashar

Evolved from Toyota’s shop floor in Japan, lean bundles are universally accepted for boosting manufacturing performance. However, extant literature shows mixed findings on the…

Abstract

Purpose

Evolved from Toyota’s shop floor in Japan, lean bundles are universally accepted for boosting manufacturing performance. However, extant literature shows mixed findings on the effectiveness of lean bundles in non-Japanese settings. This meta-analysis is aimed at understanding the influence of national culture (NC) differences on the lean bundles-performance relationships.

Design/methodology/approach

A total of 224 effects from 12,569 observations across 48 empirical studies from 14 countries are meta-analyzed. Also, weighted least squares (WLS) meta-regression using NC scores from the Global Leadership and Organizational Behavior Effectiveness (GLOBE) study are conducted to test the moderating effect of NC dimensions.

Findings

The meta-analysis reveals a positive association between the lean bundles and firm performance; though, the strength of the association varies across the individual lean bundles. The meta-regression results show that lean practices are more effective in countries that value high future orientation, high collectivism, low-performance orientation and high assertiveness.

Originality/value

The results contribute to the literature on the role of local cultural influence on strategies and decisions related to the implementation of continuous improvement (CI) programs in cross-cultural settings.

Details

The TQM Journal, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1754-2731

Keywords

Article
Publication date: 6 January 2023

Vijayeta Malla

This study aims to analyze and understand mutual relationships between lean and agile enabling factors in the context of the construction domain and put forth the most driving and…

Abstract

Purpose

This study aims to analyze and understand mutual relationships between lean and agile enabling factors in the context of the construction domain and put forth the most driving and dependent enablers for a hybrid lean–agile system (HLAS).

Design/methodology/approach

A threefold research flow is adopted. First, the content analysis of literature stemmed from the identification of preliminary enablers (n = 26). Second, a questionnaire survey (n = 101) is administered to downsize enablers to ten using the relative importance index. Further, in the third phase, interpretive structural modeling (ISM) and the cross-impact matrix multiplication applied to classification analysis were performed amid the ten key enablers through pairwise interactions from subject matter experts (n = 19). Hierarchical representation of enablers has been presented, which facilitates a conceptual model for application in the construction industry.

Findings

The ISM model demonstrates a three leveled classification structure that showcases direct and transitive relationships among various enablers. “Use of project management tools” is the driving enabler, followed by “collaborative and common data platform working” and “institution of team training” are critical enablers to HLAS adoption.

Originality/value

A structured way of identification of interdependent among lean–agile is a vital unique contribution to this study. The results serve as a knowledge base for practical adoption of HLAS and may prove to be influential in developing a framework for easier adoption in developing countries.

Details

Construction Innovation , vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1471-4175

Keywords

Article
Publication date: 12 March 2024

Daryl John Powell, Désirée A. Laubengaier, Guilherme Luz Tortorella, Henrik Saabye, Jiju Antony and Raffaella Cagliano

The purpose of this paper is to examine the digitalization of operational processes and activities in lean manufacturing firms and explore the associated learning implications…

Abstract

Purpose

The purpose of this paper is to examine the digitalization of operational processes and activities in lean manufacturing firms and explore the associated learning implications through the lens of cumulative capability theory.

Design/methodology/approach

Adopting a multiple-case design, we examine four cases of digitalization initiatives within lean manufacturing firms. We collected data through semi-structured interviews and direct observations during site visits.

Findings

The study uncovers the development of learning capabilities as a result of integrating lean and digitalization. We find that digitalization in lean manufacturing firms contributes to the development of both routinized and evolutionary learning capabilities in a cumulative fashion.

Originality/value

The study adds nuance to the limited theoretical understanding of the integration of lean and digitalization by showing how it cumulatively develops the learning capabilities of lean manufacturing firms. As such, the study supports the robustness of cumulative capability theory. We further contribute to research by offering empirical support for the cumulative nature of learning.

Details

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

Keywords

Article
Publication date: 15 May 2024

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.

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: 3 October 2023

Neeraj Kumar Jha, Naga Vamsi Krishna Jasti, Phaneendra Kiran Chaganti, Srinivas Kota and Gaurav Nagpal

Sustainable production (SP) is an efficient and influential approach of production for Indian manufacturing industries as it preserves the social, environmental and economic…

Abstract

Purpose

Sustainable production (SP) is an efficient and influential approach of production for Indian manufacturing industries as it preserves the social, environmental and economic aspects of production activities altogether. The objective of this research work is to investigate the implementation status of SP practices in Indian manufacturing industries by utilizing empirical survey methodology.

Design/methodology/approach

A questionnaire survey methodology was adapted, and the questionnaire was prepared by intense literature survey along with by opinions from experts in the field of SP. This questionnaire was sent to 753 different organizations at different locations across India. This study collected responses from manufacturing industries as per 2021 directory of Confederation of Indian Industries for the duration of 7 week. Top level managers were the target respondents. The study propagated with 242 responses which were observed complete in all respects.

Findings

The study identified that though the majority of the organizations are claiming to follow SP practices since long time, they actually are lagging in proper understanding SP practices. Majority of them are implementing it in specific departments in their organization. They are coming across multiple barriers in the implementation of SP practices among which unrecognized financial benefits and lack of proper government policies are prime. The study suggests that the Indian organizations needs feasible framework with adaptable guidelines.

Research limitations/implications

This work is centered towards manufacturing organizations and targets only the leading industrial sectors in India. Thus, the outcomes of this study may not be generalized for all the sectors of Indian industries. Additionally, it can also be assumed that higher number of responses would have contributed to more clear visualization of implementation status of SP practices among Indian industries.

Originality/value

Sustainable approaches in production activities are very lucrative for industries worldwide, due to their advantages. Numerous researchers are also putting their efforts to explore more about various aspects of sustainability. Mostly they are focusing on single or few aspects of SP and its implementation in particular region or country. Very few research works are dedicated to knowing the implementation status of SP in Indian manufacturing industries and they are limited in various aspects. This study presents a dedicated approach to investigate the implementation status of SP practices in Indian manufacturing industries.

Details

The TQM Journal, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1754-2731

Keywords

Article
Publication date: 20 December 2023

Jorge Mendes Monteiro, Diamantino Torres, Ana Luísa Ramos and Carina Pimentel

This study aims to research the usage of virtual reality as a tool to train employees in a changeover process in a company, and if it guarantees the same level of quality…

Abstract

Purpose

This study aims to research the usage of virtual reality as a tool to train employees in a changeover process in a company, and if it guarantees the same level of quality. Moreover, another goal is to understand how it can influence the machines’ availability, reducing the number of hours a machine is stopped to perform training sessions.

Design/methodology/approach

To achieve the goals proposed, the action research strategy was used. After defining the context and purpose, two full cycles were applied, composed by five activities: diagnosis, action planning, action taking, action evaluation and specify the learning.

Findings

The results are extremely satisfactory. On the one hand, it can be concluded that virtual reality is a reliable training tool, guaranteeing proper training to the employees. On the other hand, based on the previous point, the researchers were able to conclude that it is possible to increase machines’ availability, reducing by 50% the time needed to have the machines stopped to run a changeover training.

Originality/value

To the authors’ knowledge, this is the first study to use the action research strategy to develop a virtual reality simulation as a training tool for machines’ changeover in the automotive industry.

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: 20 October 2023

Joonhwan In, Randy Bradley, Bogdan C. Bichescu and Sumin Han

This study aims to examine the performance implications of an information governance (IG) framework for managing, controlling access to and securing information, focusing on (1…

Abstract

Purpose

This study aims to examine the performance implications of an information governance (IG) framework for managing, controlling access to and securing information, focusing on (1) the performance benefits of an organization's IG orientation and (2) how the configuration of IG orientation and supply chain (SC) strategy type relate to performance outcomes.

Design/methodology/approach

This study leverages multiple secondary sources for US hospitals, serving as the context for the study. It also employs cluster analysis to develop an SC strategy taxonomy, namely sophisticated and delivery-focused SC strategies. The proposed research model is tested using a robust regression to mitigate the influence of outliers and produce more accurate estimates.

Findings

IG orientation is positively associated with financial performance and patient experience, and IG-oriented hospitals with a sophisticated SC strategy realize more financial benefits and achieve better patient care experiences compared to other configurations. Regardless of SC strategy type, IG-oriented hospitals offer better care experiences than non-IG-oriented hospitals.

Practical implications

This paper offers empirical evidence that a hospital's IG orientation and SC strategy jointly affect financial outcomes and patient experience. For hospitals, an organization-wide framework for governing information streamlines both intra- and inter-organizational information flows and improves care delivery throughout a patient's care experience.

Originality/value

This is one of a few studies that empirically examine the performance implications of governance of information in the domain of supply chain management (SCM). This study also develops an SC strategy taxonomy for the healthcare context and offers a springboard for research in service SC strategy.

Details

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

Keywords

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