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Article
Publication date: 13 June 2016

Giuliano Almeida Marodin, Alejandro Germán Frank, Guilherme Luz Tortorella and Tarcisio Abreu Saurin

This paper aims to understand the patterns of lean production implementation, and the relationship between three context factors (i.e. firm size, positions within the supply chain…

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Abstract

Purpose

This paper aims to understand the patterns of lean production implementation, and the relationship between three context factors (i.e. firm size, positions within the supply chain and time length of the lean initiative) and the adoption of lean production practices in firms of the automotive supply chain in Brazil.

Design/methodology/approach

The authors collected data from 65 companies of the automotive supply chain in Brazil. For data analysis, first a cluster analysis was performed to identify common characteristics in the companies’ context factors when considering patterns of lean implementation. Then, multivariate analysis of variance was used to investigate the differences between the context factors and the degree of use of lean practices.

Findings

High lean adopters had better performance than low lean adopters in terms of lead time, inventory and turnover. Firms at the first and second tier of the automotive supply chain were “leaner” than firms at the third tier. Large-sized firms were more likely to have a higher degree of use of lean practices than medium and smaller ones. Some, but not all, lean practices followed these patterns. Results also showed that some lean practices were most commonly adopted at the beginning of the lean journey, whereas others took more time to mature.

Originality/value

This paper demonstrated how lean practices were implemented at different positions within the supply chain, and the patterns of implementation often followed. It also considers lean in the context of developing countries such as Brazil.

Details

Supply Chain Management: An International Journal, vol. 21 no. 4
Type: Research Article
ISSN: 1359-8546

Keywords

Article
Publication date: 6 February 2017

Dàvid Losonci, Richárd Kása, Krisztina Demeter, Balázs Heidrich and István Jenei

The purpose of this paper to examine the impact of shop floor (SF) culture (organizational culture (OC) perceived by workers) and SF subcultures assessed by the competing values…

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Abstract

Purpose

The purpose of this paper to examine the impact of shop floor (SF) culture (organizational culture (OC) perceived by workers) and SF subcultures assessed by the competing values framework (CVF) on the perceived use of lean production (LP) practices.

Design/methodology/approach

The authors analyse questionnaires completed by workers at the single case company undergoing a commonplace lean transformation. The survey items cover both LP items and CVF statements. The propositions are analysed applying cluster analysis and regression.

Findings

At the case company, the multidimensionality of SF culture only partially exists, and the perceived use of LP practices shows little connection to OC. The considerable differences between SF culture and SF subcultures on the one hand and among SF subcultures on the other hand indicate the existence of a special multidimensional SF culture. Altogether, SF culture’s impact on LP is weak.

Practical implications

Managers should rethink the usual lean implementation pathways and understand how values pervade SF culture and how culture types impact the perceived use of LP practices at the SF. Managers could face a trade-off: smoother lean transition by engaging in SF subculture-specific transitions and reinforcing it or by developing a homogenous lean SF culture.

Originality/value

To the best of the authors’ knowledge, this is the first empirical attempt to understand the impact of SF culture on the perceived use of LP practices by adopting a validated OC measurement tool. Furthermore, the study provides insight into workers’ subcultures.

Details

International Journal of Operations & Production Management, vol. 37 no. 2
Type: Research Article
ISSN: 0144-3577

Keywords

Article
Publication date: 19 May 2023

Palash Saha, Subrata Talapatra, H.M. Belal, Victoria Jackson, Amanda Mason and Olatunde Durowoju

This study aims to investigate the influence of the interrelationship between the deployment of Industry 4.0 (I4.0) technologies and the application of lean production (LP

Abstract

Purpose

This study aims to investigate the influence of the interrelationship between the deployment of Industry 4.0 (I4.0) technologies and the application of lean production (LP) practices on the degree of organizational sustainability performance (SP) enhancement of the Bangladeshi ready-made garment (RMG) sector.

Design/methodology/approach

Previously, researchers have applied the resource-based view (RBV) or dynamic capability view (DCV) to describe the interaction of resources and capacities (technologies, management practices, SP) to analyze their effectiveness. However, in light of several contemporary academic discussions, this study contends that these organizational views are inappropriate for explicating SP. Hence, as the foundation of this study’s theoretical framework, the authors used the practice-based view (PBV), which is recommended as a useful window to evaluate the function of practices that are common and simple to emulate in execution. To test the theoretical framework and research hypothesis, this study used partial least square (PLS) analysis. For that, the authors carried out a systematic survey to collect data from 80 Bangladeshi RMG factories.

Findings

The results of this research imply that LP is a crucial factor in enhancing organizational SP. Moreover, the results also indicate that the adoption of I4.0 technologies along with LP can assist in delivering the lean objectives more efficiently and, therefore, the combined application of LP practices and I4.0 technologies play a significant role in enhancing organizational SP.

Originality/value

Though the present literature indicates the probable significant association between LP and SP or I4.0 technologies and SP, no study, with the best of the authors’ knowledge, has empirically examined the combined impacts of correlation between LP and I4.0 on SP. This is also a unique study to apply the PBV theory to explain the organizational SP through the combination of common resources and technologies.

Details

Journal of Business & Industrial Marketing, vol. 38 no. 12
Type: Research Article
ISSN: 0885-8624

Keywords

Article
Publication date: 2 March 2020

Guilherme Tortorella, Rapinder Sawhney, Daniel Jurburg, Istefani Carisio de Paula, Diego Tlapa and Matthias Thurer

The objective of this research is twofold. First, we aim at identifying the pairwise relationships between Lean Production (LP) practices and Industry 4.0 (I4.0) technologies…

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Abstract

Purpose

The objective of this research is twofold. First, we aim at identifying the pairwise relationships between Lean Production (LP) practices and Industry 4.0 (I4.0) technologies. Second, based on these results, we propose a framework for Lean Automation (LA) implementation, in which I4.0 technologies are integrated into LP practices.

Design/methodology/approach

To achieve that, a cross-sector survey was performed with 147 manufacturers that are undergoing a LP implementation aided by novel information and communication technologies from I4.0. Multivariate data analysis was applied in order to underpin the proposed framework for LA.

Findings

Findings indicate that I4.0 technologies are positively correlated with LP practices, providing evidence to bear the proposition of a LA framework that can potentially overcome traditional barriers and challenges of a LP implementation.

Originality/value

As previous studies have approached LA implementation from a narrow perspective or including a limited set of LP practices and I4.0 technologies, the proposition of an integrated framework unfolds a wider range of synergistic implementations that may corroborate to a holistic approach for continuous improvement in the Fourth Industrial Revolution era.

Details

Journal of Manufacturing Technology Management, vol. 32 no. 3
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 10 September 2021

Umair Manzoor, Sajjad Ahmad Baig, Muhammad Hashim, Abdul Sami, Hakeem-Ur Rehman and Ifrah Sajjad

In today's global economy, developing supply chain agility (SCA) and lean practices (LP) as resource-based view and dynamic capabilities are essential for firms to sustain their…

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Abstract

Purpose

In today's global economy, developing supply chain agility (SCA) and lean practices (LP) as resource-based view and dynamic capabilities are essential for firms to sustain their competitive advantage (CA) and enhance their operational performance (OP). The purpose of this paper is to develop and empirically test a framework to investigate how CA is achieved through SCA and LP and how these, in turn, can enhance a firm's OP.

Design/methodology/approach

For data collection, the authors adopted the survey method using self-administered questionnaires. Two-source survey data were collected in two rounds (separated by a two-month lag time) from supply chain managers, operational managers and general managers. The purpose of collecting data in two rounds was to reduce common-method bias. Likert scale (1–5) was used in the questionnaire. Smart PLS 3 and SPSS 23 were used for the data analysis purpose.

Findings

SCA was found to directly and positively affect OP. LP also positively affected OP. In addition, CA fully mediated the relationship between SCA, LP and OP.

Practical implications

This study encourages the managers of manufacturing firms to adapt LP and their supply chains (SCs) to become agile and leverage the advantages of their implementation to improve their OP and succeed in the market.

Originality/value

This study is one of the first to investigate the effect of SCA and LP on OP. Furthermore, the first study examines CA's mediating impact on the relationship between SCA, LP and OP.

Details

The TQM Journal, vol. 34 no. 5
Type: Research Article
ISSN: 1754-2731

Keywords

Article
Publication date: 18 July 2020

Luciano Novais, Juan Manuel Maqueira Marín and José Moyano-Fuentes

With support from the dynamic capabilities theory, this paper examines the role of Cloud Computing technology use in logistics (Cloud-Supported Logistics) and its effect on…

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Abstract

Purpose

With support from the dynamic capabilities theory, this paper examines the role of Cloud Computing technology use in logistics (Cloud-Supported Logistics) and its effect on business results in Lean manufacturing management (Lean Production implementation) and Supply Chain Integration contexts.

Design/methodology/approach

Using the survey method, a random sample of 260 companies in intermediate positions in their supply chains was gathered from a population of 1,717 Spanish companies and used to test five hypotheses. The data were collected by telephone survey using a computerised system with a response rate of 15.6% (260 valid questionnaires). Structural equation modelling was used to test the five proposed hypotheses.

Findings

The findings indicate that Cloud-Supported Logistics use plays an important role in achieving better business results in Lean Production environments. Lean Production has been found to have both a direct effect and an even more powerful indirect effect on performance through the Cloud-Supported Logistics and Supply Chain Integration that these technologies produce. Supply Chain Integration is also found to have a mediating effect in the Cloud-Supported Logistics–performance relationship.

Originality/value

This study is valuable for academics and practitioners as it provides evidence of the relevant role played by Cloud-Supported Logistics in Lean Production implementation contexts. Cloud-Supported Logistics and Lean Production are strategically and operationally linked and their joint use results in Supply Chain Integration and better business performance.

Details

The International Journal of Logistics Management, vol. 31 no. 3
Type: Research Article
ISSN: 0957-4093

Keywords

Article
Publication date: 1 May 2006

Tomas Bonavia and Juan Antonio Marin

To determine the degree of use of some of the most representative lean production (LP) practices in the Spanish ceramic tile industry, their relationship with plant size and their…

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Abstract

Purpose

To determine the degree of use of some of the most representative lean production (LP) practices in the Spanish ceramic tile industry, their relationship with plant size and their effect on the operational performance of the companies in the sector.

Design/methodology/approach

A questionnaire was developed for data collection. Findings are presented from 76 companies (79.17 per cent of the total sample) that specialise in single firing ceramics.

Findings

In the sector under study, there is one set of practices that have as yet scarcely been implemented (group technology, kanban, reduction of set‐up time, development of multi‐function employees and visual factory) and another set whose use is fairly widespread (standardisation of operations, total productive maintenance and quality controls). The degree of their respective use depends on a firm's size. Very few correlations appear between the degree of use of any specific LP practice in isolation and the operational indicators.

Research limitations/implications

For certain variables we found very little variation between the firms in our sample. Moreover, many firms did not have available the data needed for calculating capacity utilisation, and hence we have not been able to check its effects in our analysis.

Practical implications

The paper presents data for reflecting on the application of different LP practices in isolation and on the impediments limiting the use of some of them in the sector.

Originality/value

The paper extends the work of other researchers by focusing on a sector and a country that have been very little studied until now. The sample consists of a set of firms that are fairly homogeneous; this facilitates analysing the relationships between the selected variables while keeping other variables controlled.

Details

International Journal of Operations & Production Management, vol. 26 no. 5
Type: Research Article
ISSN: 0144-3577

Keywords

Article
Publication date: 5 September 2008

Jordi Olivella, Lluís Cuatrecasas and Nestor Gavilan

The purpose of this paper is to obtain and to expose work organisation practices common to the factories that successfully follow lean production (LP) principles.

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Abstract

Purpose

The purpose of this paper is to obtain and to expose work organisation practices common to the factories that successfully follow lean production (LP) principles.

Design/methodology/approach

Analysis of the literature and interviews with experts.

Findings

An analysis of the literature reveals clear connections between work organisation practices and LP. However, general reports on LP barely deal with work organisation. A set of work organisation objectives for LP was established for the authors and interviewed experts and analysed by reviewing the literature. Similarities are found between the different sources in terms of defining a set of policies and practices covering all the aspects of work organisation. It is shown that there are indeed work organisation practices characteristic of LP.

Originality/value

This paper is believed to be the first complete analysis of work organisation practices for LP.

Details

Journal of Manufacturing Technology Management, vol. 19 no. 7
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 29 November 2018

Anup Prabhakarrao Chaple, Balkrishna Eknath Narkhede, Milind M. Akarte and Rakesh Raut

Firms have been adopting lean manufacturing to improve their business performances. However, they are facing failures or less success in implementation, mainly due to lack of…

Abstract

Purpose

Firms have been adopting lean manufacturing to improve their business performances. However, they are facing failures or less success in implementation, mainly due to lack of understanding in relating the lean practices (LPs) from the required performance measures perspective. In view of the lack of research and the importance of understanding them, the purpose of this paper is to prioritize LPs.

Design/methodology/approach

As LPs are scattered in the literature and a variety of performance measures are used, an extensive literature review is first carried out to identify the LPs and performance measures. The blend of interpretive structural modeling and interpretive ranking process interpretive tools is adopted in establishing the contextual relationship among LPs and then ranking them based on the performance measures. A three-dimensional priority matrix is proposed for better explanation of the results.

Findings

The proposed framework can help firms better understand LPs and their levels of importance in lean implementation.

Research limitations/implications

The involvement of lean experts may produce some bias in evaluating the LPs.

Practical implications

The proposed framework can help practitioners to develop an industry-specific road-map for the result-oriented LP implementation. Based on the area of performance to be improved, practitioners can prioritize LPs for implementation.

Originality/value

This is the first study that provides a comprehensive review of LPs available in the literature and prioritizes them in accordance with performance with interpretive tools.

Article
Publication date: 6 July 2012

Paul Hong, James Jungbae Roh and Greg Rawski

With increasing emphasis on the environment, firms are required to include sustainability practices at all levels – strategic, operational, and outcome measures. The purpose of…

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Abstract

Purpose

With increasing emphasis on the environment, firms are required to include sustainability practices at all levels – strategic, operational, and outcome measures. The purpose of this paper is to present a research model that defines sustainability practices in the context of the competitive business environment, strategic driver, operational and supply chain practices, and performance outcomes.

Design/methodology/approach

This paper identifies research gaps in the areas of integration of sustainability practices across functional levels within firms and across networks. In total, 379 companies were analyzed in structural equation modeling.

Findings

This study has three important findings: First, firms striving for responsiveness to market and customers also improve environmental performance; second, this study confirms lean practices as an important mediator to achieve excellent environmental performance; third, the focal company takes the lead in achieving environmental performance, and suppliers are in the supportive circle of influence.

Originality/value

This study provides a research model based on rich theoretical support. It further provides reliable measures of sustainability practices as benchmark tools.

1 – 10 of 364