Abu Hamja, Peter Hasle and David Hansen
Lean manufacturing has the potential for simultaneously improving the competitiveness and the social sustainability of the apparel industry in developing countries. However, there…
Abstract
Purpose
Lean manufacturing has the potential for simultaneously improving the competitiveness and the social sustainability of the apparel industry in developing countries. However, there is limited research on the ways to a successful lean implementation in developing countries and with an emphasis on occupational health and safety (OHS) improvement.
Design/methodology/approach
The paper investigates four cases of lean implementation in garment factories and uses the design science research strategy, building on the context-intervention-mechanism-outcome (CIMO) framework to identify explanatory mechanisms that can be used for designing future action.
Findings
The study identifies tangible mechanisms that can lead to successful lean implementation. The most important mechanisms relate to practical top management support, worker involvement, application of lean tools and training.
Practical implications
The findings of this study can guide better lean implementation for the many garment factories in developing countries.
Originality/value
While the lean literature provides general recommendations for lean implementation, knowledge about the transfer mechanisms in developing countries as well as the connections between lean and OHS is limited. This paper contributes to lean implementation theory and to the discourse of positive lean by integrating efficiency and working conditions. In addition, the paper identifies transfer mechanisms for lean implementation in the garment industry in a developing country.
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Azim Mohammad, Abu Hamja and Peter Hasle
Shorter lead time with low price and quality product demand is pivotal in the garment industry. Pressure on production lead time stresses the importance of reducing style…
Abstract
Purpose
Shorter lead time with low price and quality product demand is pivotal in the garment industry. Pressure on production lead time stresses the importance of reducing style changeover time in manufacturing factories, and this paper aims to contribute to solving the challenge by showing how the single minute exchange of die (SMED) methodology in practice can be adapted to garment factories in developing countries.
Design/methodology/approach
The paper investigates three cases of SMED implementation integrated with responsible, accountable, consulted, informed (RACI) matrices in garment factories in an action research approach. Both quantitative and qualitative methods are applied.
Findings
The study shows a reduction of 50% to 64% of changeover time with SMED implementation measured with two key indicators – throughout time and time to reach peak production. Moreover, the implementation depends on the application of the RACI matrix for the distribution of responsibility as well as integration with the basic production flow before and after the application of SMED.
Practical implications
The study can guide better SMED implementation in garment factories with limited investment by stressing the need to adapt to the specifics of the garment industry, secure the division of responsibility and integrate SMED in the production flow before and after the changeover.
Originality/value
Limited research on the application of SMED in the garment industry. This paper contributes to understanding the specific conditions for successful implementation in the garment industry in developing countries and addresses additional activities that help secure a sustainable implementation process.
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Syeda Ayesha Wadood, Muhammad Shakeel Sadiq Jajja, Kamran Ali Chatha and Sami Farooq
This study draws on the systems perspective to study the individual and combined interaction effect of lean management (LM) and sustainability management (SM) on the…
Abstract
Purpose
This study draws on the systems perspective to study the individual and combined interaction effect of lean management (LM) and sustainability management (SM) on the organization's triple bottom line (TBL) performance.
Design/methodology/approach
The study employs structural equation modeling to test the proposed hypotheses using data from the sixth version of the International Manufacturing Strategy Survey (IMSS VI).
Findings
The study finds that LM is positively related to all dimensions of the TBL performance. In contrast, SM is positively related to social and environmental performance and negatively related to economic performance. Finally, by finding that the interaction between LM and (SM) is positive for social and environmental performance, this study not only confirms that LM is an enabler for sustainability, but it also supports that the two paradigms are mutually compatible and reinforcing.
Practical implications
The findings imply that practitioners pursuing both LM and SM should leverage their mutual positive effects and balance the unintended effects of implementing isolated bundles by implementing them together as a complete socio-technical system. Their combined impact on the TBL performance will outweigh the sum of their individual effects in the case of isolated implementations.
Originality/value
In contrast with the extant literature, this study proposes that LM and SM make parts of one system as opposed to one correlated with the other or having a positive causal effect on the other. Taking an integrated systems approach, the study empirically verifies the “mutual compatibility” of the lean and sustainability paradigms argument, with regard to their effect on the TBL performance.
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Sheak Salman, Hasin Md. Muhtasim Taqi, S.M. Shafaat Akhter Nur, Usama Awan and Syed Mithun Ali
This study aims to address the critical challenge of implementing lean manufacturing (LM) in emerging economies, where sustainability complexities on the production floor hinder…
Abstract
Purpose
This study aims to address the critical challenge of implementing lean manufacturing (LM) in emerging economies, where sustainability complexities on the production floor hinder production efficiency and the transition towards a circular economy (CE). Addressing a gap in existing research, the paper introduces a path analysis model to systematically identify, prioritize and overcome LM implementation barriers, aiming to enhance performance through strategic removal.
Design/methodology/approach
The authors used a mixed-method approach, combining empirical survey data with literature reviews to pinpoint key LM barriers. Using the grey-based Decision-Making Trial and Evaluation Laboratory (DEMATEL) along with the Network Knowledge (NK) method, they mapped causal relationships and barrier intensities. This formed the basis for developing a path simulation algorithm, integrating heuristic considerations for practical decision-making.
Findings
This analysis reveals that the primary barriers to LM adoption is the negative perception and inadequate understanding of lean tools and CE principles. The study provides a strategic framework for managers, offering new insights into barrier prioritization and overcoming strategies to facilitate successful LM adoption.
Research limitations/implications
This research provides a strategic pathway for overcoming LM implementation barriers, empowering managers in emerging economies to enhance sustainability and competitive advantage through LM and CE integration. It emphasizes the significance of structured barrier management in the manufacturing sector.
Originality/value
This research pioneers a systematic exploration of LM implementation barriers in the CE context, making a significant contribution to the literature. It identifies, evaluates barriers and proposes a practical model for overcoming them, enriching sustainable manufacturing practices in emerging markets.
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Qi Sun, Ying Zhang, Yue Sun, Yi-Jun Chen, Xin Li, Qian-Wen Huang, Qi-Zheng Li and Laili Wang
With the accumulation of theoretical research and practical experience in the field of garment production research, it is imperative to methodically analyze and reflect on the…
Abstract
Purpose
With the accumulation of theoretical research and practical experience in the field of garment production research, it is imperative to methodically analyze and reflect on the achievements that have been made. This review aims to systematically map the academic landscape of research articles on garment production, elucidate the evolutionary trajectory of this discipline, identify emerging research frontiers and provide insights into its prospects.
Design/methodology/approach
Based on the Web of Science core database, 307 research articles were systematically analyzed by CiteSpace software. The study employed bibliometric and thematic analyses to offer in-depth insights into the dynamics and evolution of research on garment production.
Findings
Results reveal that keyword analysis emphasizes the significance of topics such as apparel assembly line, lean production, circular economy, fuzzy logic, global production networks, social sustainability and supply chain management in garment production research. Citation analysis demonstrates that articles related to environmental impact, supply chain management, production process and production technology constitute the knowledge base and core of garment production research. Eight principal research themes emerge: customized garment production, production technology, quality assurance, equipment, production lines, supply chain management, environmental impact and social and human impact. Future research hotspots will focus more on sustainable, intelligent and digital clothing production.
Originality/value
The findings systematically sort out the hotspots and trends in garment production, establish knowledge structures and display them through intuitive representations. The rich insights set the stage for the development of garment production and provide future guidance for theoretical research.
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Abu Daud Lutful ZamirKhan, Mohammad Rabiul Basher Rubel and Daisy Mui Hung Kee
This research aims to investigate the impact of psychosocial safety climate (PSC) on employee quitting intention (QI) and organizational citizenship behavior (OCB), considering…
Abstract
Purpose
This research aims to investigate the impact of psychosocial safety climate (PSC) on employee quitting intention (QI) and organizational citizenship behavior (OCB), considering the moderating effects of workload and organizational training.
Design/methodology/approach
The research adopts a cross-sectional approach, involving 151 employees from the apparel manufacturing industry in Bangladesh who participated in the survey. Data analysis is conducted using SmartPLS.
Findings
The study reveals that PSC contributes to prolonged employee tenure and fosters positive organizational citizenship behavior. Workload and organizational training play significant moderating roles, influencing the negative and positive effects of PSC on QI and OCB, respectively.
Research limitations/implications
While the PSC model has been studied, there are ample opportunities to enhance and validate theoretical models exploring the moderating impact of job demands and resources on PSC-outcome relationships.
Originality/value
This study serves as an exploration of the influence of working conditions on the outcomes of PSC within the context of the manufacturing industry in a non-Western developing country like Bangladesh. Moreover, it looks into the moderating roles of workload and organizational training to extend the PSC model.
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Nagamani Subramanian and M. Suresh
This study aims to investigate the implementation of lean human resource management (HRM) practices in manufacturing small- and medium-sized enterprises (SMEs) and explore how…
Abstract
Purpose
This study aims to investigate the implementation of lean human resource management (HRM) practices in manufacturing small- and medium-sized enterprises (SMEs) and explore how various factors interact to influence their successful adoption. By exploring the interplay among these factors, the research seeks to identify key drivers affecting the adoption of lean HRM in manufacturing SMEs. Ultimately, the research intends to provide insights that can guide organisations, practitioners and policymakers in effectively implementing lean HRM practices to enhance operational efficiency, workforce engagement and competitiveness within the manufacturing SME sector.
Design/methodology/approach
The study combined total interpretive structural modelling (TISM) and Matrice d'Impacts Croisés Multiplication Appliquée à un Classement (MICMAC) analysis. TISM helped in understanding the hierarchical relationship among different factors influencing lean HRM implementation, whereas MICMAC analysis provided insights into the level of influence and dependence of each factor on others.
Findings
The research revealed that “top management support” emerged as the most independent factor, indicating that strong support from top management is crucial for initiating and sustaining lean HRM practices in manufacturing SMEs. On the other hand, “employee involvement and empowerment” was identified as the most dependent factor, suggesting that fostering a culture of employee engagement and empowerment greatly relies on the successful implementation of lean HRM practices.
Research limitations/implications
While the study provided valuable insights, it has certain limitations. The research was conducted within the specific context of manufacturing SMEs, which might limit the generalizability of the findings to other industries. Expert opinions introduce subjectivity in data collection. Additionally, the study may not cover all critical factors, allowing room for further exploration in future research.
Practical implications
The findings have practical implications for manufacturing SMEs aiming to implement lean HRM practices. Recognising the pivotal role of top management support, organisations should invest in cultivating a strong leadership commitment to lean HRM initiatives. Furthermore, enhancing employee involvement and empowerment can lead to better adoption of lean HRM practices, resulting in improved operational efficiency and overall competitiveness.
Originality/value
This research contributes to the field by offering a comprehensive exploration of the interplay among factors influencing lean HRM implementation. The use of TISM and MICMAC analysis provides a unique perspective on the relationship dynamics between these factors, allowing for a nuanced understanding of their roles in the adoption of lean HRM practices in manufacturing SMEs. The identification of “top management support” as the most independent and “employee involvement and empowerment” as the most dependent factors adds original insights to the existing literature.
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Nagamani Subramanian, Suresh M. and John William A.
Demanding and highly competitive business environment has stimulated small and medium enterprises (SMEs) to restructure their manufacturing practices. Lean manufacturing (LM), a…
Abstract
Purpose
Demanding and highly competitive business environment has stimulated small and medium enterprises (SMEs) to restructure their manufacturing practices. Lean manufacturing (LM), a comprehensive alternative, is now being adopted, notably by manufacturing organizations, to increase business effectiveness and performance through a variety of lean approaches. Lean implementation, however, ran into a number of difficulties, which showed that non-technical factors such as human-related practices must also be integrated if lean is to be successful. This study aims to examine a thorough overview of the various human-related lean practices (HRLP) mentioned in recent literature and to determine which of them is more pertinent to a successful LM implementation in SMEs.
Design/methodology/approach
A total of 193 publications published in 45 journals between 2013 and 2023 and based on the 4 reputable publishers, namely, Science Direct, Emerald Online, Taylor and Francis and Springer Link, were gathered based on a systematic literature review of peer-reviewed journal articles in LM.
Findings
The amount of research on human resource management and lean management that has been conducted has increased dramatically during the past few years. The outcome of this study will offer a thorough analysis of soft lean practices found in the LM literature that manufacturing SMEs should take into account while implementing lean.
Research limitations/implications
The scope of this research is restricted to a survey of scholarly works using the terms “Lean manufacturing” or “Lean production” as well as “human” or “people” or “soft-lean practices” in the title. Furthermore, only works published in scholarly publications that have undergone peer review were included. Also, due to the authors’ linguistic restrictions, only English articles were used. The HRLP linked to a smooth lean transition are described in this research. Thus, it can be used to assist the production and human resource departments in raising an organization’s long-term performance.
Originality/value
The study gives researchers a better grasp of the direction the subject is taking and what gaps still exist, which aids them in focusing their research on HRLP in small- and medium-sized businesses.
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Jhumana Akter, Shuvo Dip Datta, Mobasshira Islam, Bassam A. Tayeh, Sadia Ahmmed Sraboni and Niloy Das
The purpose of this research paper is to investigate and evaluate the impacts of utilising Building Information Modelling (BIM) as a lean management tool in Bangladesh's…
Abstract
Purpose
The purpose of this research paper is to investigate and evaluate the impacts of utilising Building Information Modelling (BIM) as a lean management tool in Bangladesh's construction management field. The paper explores how adopting BIM as a lean management tool can improve and expedite a number of processes in building projects, which will ultimately increase project success, cost-effectiveness and efficiency.
Design/methodology/approach
A comprehensive survey was conducted to investigate how BIM deployment as a lean management tool affected project outcomes. This research involved a structured survey amongst construction professionals and a case study on a real project in Bangladesh to assess the effects of using BIM as a lean management tool. The data collected from 112 respondents were analysed statistically and qualitatively to identify the effect of BIM as a lean management tool. Additionally, several software tools, including Revit, Navisworks, Design Review and BIM 360, were used to compare conventional and BIM-based methods.
Findings
The research findings demonstrate that utilising BIM practices improves the quality and safety of construction in Bangladesh. The “Improving the quality of construction” (RII = 0.732) achieved the highest rank in the questionnaire survey. In addition, the case study represents that the construction industry can benefit from BIM-based project management. The BIM implementation can shorten the design process by over 50% and save up to 1.5 weeks by minimising idling time. By applying BIM, it is possible to avoid a price rise of roughly 2.5% and a delay of about 11.9% of the original contract period.
Practical implications
The significance of the results goes beyond the direct advantages of the project's achievements. The successful integration of BIM as a lean management tool in Bangladesh's construction sector suggests transformative potential for the industry. The enhanced coordination and decreased errors point to a future where construction projects can achieve higher levels of precision and reliability. The improved efficiency observed implies a more sustainable and cost-effective future for construction projects in the region.
Originality/value
The research provides a unique perspective on the impact of BIM implementation on project outcomes. It includes a comprehensive survey on BIM adoption as a lean management tool, gathering real-world experiences from construction professionals in Bangladesh. The case study explores the practical implications and advantages of implementing BIM in construction projects. By comparing conventional methods with BIM-based approaches and utilising BIM software, the study contributes value to the construction sector.