Bharat Singh Patel, Murali Sambasivan, R. Panimalar and R. Hari Krishna
The purpose of this study is to categorize and analyse the drivers and barriers of Lean Manufacturing (LM) and subsequently, based on the structural model develop a house of lean…
Abstract
Purpose
The purpose of this study is to categorize and analyse the drivers and barriers of Lean Manufacturing (LM) and subsequently, based on the structural model develop a house of lean management which will give an idea to the academicians and practitioners about the factors that are critical to implement lean practices in an organization.
Design/methodology/approach
A list of drivers and barriers was prepared based on the literature review and opinions from experts. Total Interpretive Structural Modelling (TISM) was utilized to build a structural hierarchy of the drivers and barriers of LM. The structural hierarchy was utilized to build the house of lean management.
Findings
Based on the hierarchy developed, the elements (drivers and barriers) of LM are classified into three groups: bottom-level, middle-level and top-level elements. To develop a house of lean management, bottom-level of elements were considered as a foundation, middle-level elements were considered as pillars and top-level elements were considered as a beam. Finally, foundation, pillars and beam of the house were used to support the roof (which is value to customers and profitability to firm).
Practical implications
The outcome of this research can assist researchers as well as practitioners to enhance the significant drivers and to reduce the impact of hazardous barriers for the better implementation of lean practices.
Originality/value
This research is a novel approach, as it visibly demonstrates both the drivers and barriers, examines the interrelationships among them in order and shows them pictorially as the house of lean management.
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Samir Ramdas Kale, Srinivas Kota, Naga Vamsi Krishna Jasti, Gunjan Soni and Surya Prakash
The manufacturing sector has been observing various benefits by the implementation of lean manufacturing practices. However, the manufacturing sector has neglected the…
Abstract
Purpose
The manufacturing sector has been observing various benefits by the implementation of lean manufacturing practices. However, the manufacturing sector has neglected the significance of health and safety management system implementation. The purpose of this research is to propose and validate an occupational health and safety management systems (OHSMS) framework based on critical success factors and their relationships in the lean manufacturing organizations.
Design/methodology/approach
A critical literature review was conducted to identify the success factors of OHSMS. Subsequently, a questionnaire survey and semi-structured interviews were conducted with experts from process industries to consolidate the critical success factors. After consolidating the critical success factors, relationships among critical success factors were established with the help of interpretive structural modelling using a team of 12 experts from industry and academia. These established relationships helped in proposing the hierarchical implementation framework. Finally, the validation of the proposed implementation framework was carried out using structural equation modelling (SEM).
Findings
This study has identified nine broader critical success factors for implementation of OHSMS in lean manufacturing organizations, especially the process industry. Subsequently, this study has proposed an OHSMS framework with nine broader critical success factors to implement in lean manufacturing organizations. Finally, the proposed framework has been validated using SEM with an appropriate sample size.
Practical implications
This study is helpful to the organizations to implement OHSMS without losing the essence of lean manufacturing strategy. This study has proposed a framework for implementation of OHSMS in the lean manufacturing organizations, especially process industry sector. This study also provided confidence to the organization through the validation of proposed framework in the process industry.
Originality/value
To the best of the authors’ knowledge, this study is first of its kind in this field of OHSMS in lean manufacturing organizations, especially the process industry. This study has involved both academicians and industry experts to bring more robust outcomes. This study proposed a unique framework to implement OHSMS in lean manufacturing organizations. This study has considered a comprehensive literature to develop a framework for OHSMS in lean manufacturing organizations. An implementation framework was proposed by considering both the academicians’ and industry professionals’ opinions. The proposed framework was statistically validated. This will be helpful in effective implementation of OHSMS strategy in lean manufacturing organizations, especially process industry sector.
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Ali Hassanzadeh, Ebrahim Ghorbani-Kalhor, Khalil Farhadi and Jafar Abolhasani
This study’s aim is to introduce a high-performance sorbent for the removal of both anionic (Congo red; CR) and cationic (methylene blue; MB) dyes from aqueous solutions.
Abstract
Purpose
This study’s aim is to introduce a high-performance sorbent for the removal of both anionic (Congo red; CR) and cationic (methylene blue; MB) dyes from aqueous solutions.
Design/methodology/approach
Sodium silicate is adopted as a substrate for GO and AgNPs with positive charge are used as modifiers. The synthesized nanocomposite is characterized by FTIR, FESEM, EDS, BET and XRD techniques. Then, some of the most effective parameters on the removal of CR and MB dyes such as solution pH, sorbent dose, adsorption equilibrium time, primary dye concentration and salt effect are optimized using the spectrophotometry technique.
Findings
The authors successfully achieved notable maximum adsorption capacities (Qmax) of CR and MB, which were 41.15 and 37.04 mg g−1, respectively. The required equilibrium times for maximum efficiency of the developed sorbent were 10 and 15 min for CR and MB dyes, respectively. Adsorption equilibrium data present a good correlation with Langmuir isotherm, with a correlation coefficient of R2 = 0.9924 for CR and R2 = 0.9904 for MB, and kinetic studies prove that the dye adsorption process follows pseudo second-order models (CR R2 = 0.9986 and MB R2 = 0.9967).
Practical implications
The results showed that the proposed mechanism for the function of the developed sorbent in dye adsorption was based on physical and multilayer adsorption for both dyes onto the active sites of non-homogeneous sorbent.
Originality/value
The as-prepared nano-adsorbent has a high ability to remove both cationic and anionic dyes; moreover, to the high efficiency of the adsorbent, it has been tried to make its synthesis steps as simple as possible using inexpensive and available materials.
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Hari Hara Krishna Kumar Viswanathan, Punniyamoorthy Murugesan, Sundar Rengasamy and Lavanya Vilvanathan
The purpose of this study is to compare the classification learning ability of our algorithm based on boosted support vector machine (B-SVM), against other classification…
Abstract
Purpose
The purpose of this study is to compare the classification learning ability of our algorithm based on boosted support vector machine (B-SVM), against other classification techniques in predicting the credit ratings of banks. The key feature of this study is the usage of an imbalanced dataset (in the response variable/rating) with a smaller number of observations (number of banks).
Design/methodology/approach
In general, datasets in banking sector are small and imbalanced too. In this study, 23 Scheduled Commercial Banks (SCBs) have been chosen (in India), and their corresponding corporate ratings have been collated from the Indian subsidiary of reputed global rating agency. The top management of the rating agency provided 12 input (quantitative) variables that are considered essential for rating a bank within India. In order to overcome the challenge of dataset being imbalanced and having small number of observations, this study uses an algorithm, namely “Modified Boosted Support Vector Machines” (MBSVMs) proposed by Punniyamoorthy Murugesan and Sundar Rengasamy. This study also compares the classification ability of the aforementioned algorithm against other classification techniques such as multi-class SVM, back propagation neural networks, multi-class linear discriminant analysis (LDA) and k-nearest neighbors (k-NN) classification, on the basis of geometric mean (GM).
Findings
The performances of each algorithm have been compared based on one metric—the geometric mean, also known as GMean (GM). This metric typically indicates the class-wise sensitivity by using the values of products. The findings of the study prove that the proposed MBSVM technique outperforms the other techniques.
Research limitations/implications
This study provides an algorithm to predict ratings of banks where the dataset is small and imbalanced. One of the limitations of this research study is that subjective factors have not been included in our model; the sole focus is on the results generated by the models (driven by quantitative parameters). In future, studies may be conducted which may include subjective parameters (proxied by relevant and quantifiable variables).
Practical implications
Various stakeholders such as investors, regulators and central banks can predict the credit ratings of banks by themselves, by inputting appropriate data to the model.
Originality/value
In the process of rating banks, the usage of an imbalanced dataset can lessen the performance of the soft-computing techniques. In order to overcome this, the authors have come up with a novel classification approach based on “MBSVMs”, which can be used as a yardstick for such imbalanced datasets. For this purpose, through primary research, 12 features have been identified that are considered essential by the credit rating agencies.
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César Cuevas, Ignacio Mira-Solves and Antonio Verdu-Jover
In the evolving landscape of Industry 5.0 (I5.0), which emphasises sustainability, human-centricity and resilience, mapping the current interrelationship and future research…
Abstract
Purpose
In the evolving landscape of Industry 5.0 (I5.0), which emphasises sustainability, human-centricity and resilience, mapping the current interrelationship and future research directions, the role of Lean Six Sigma (LSS) methodology remains underexplored. Our study addresses this gap by examining the potential of LSS to support I5.0 while identifying areas for further investigation.
Design/methodology/approach
This study's multifaceted approach, which includes systematic literature review (SLR), bibliographic network analysis (BNA) and expert validation (EV), provides a holistic exploration of the interaction between LSS and I5.0 as the basis for well-founded conclusions.
Findings
The analysis yields several valuable insights. Firstly, it demonstrates the absence of a direct link between LSS and I5.0. Secondly, the substantial body of literature analysed establishes connections between LSS and its pillars. Thirdly, the analysis identifies points of intersection, difference and similarity between LSS and I5.0, highlighting the potential of LSS to facilitate implementation of I5.0 through its proven methodologies, continuous improvement culture, risk management, error learning, human–machine collaboration and training and skill development.
Originality/value
This study pioneers the effort to realise the latent potential of LSS in the context of I5.0. Its systematic identification of the synergies between these paradigms fills a critical gap in the literature and gives policymakers, managers and researchers a guide for informed decision-making to maximise the benefits of I5.0 for individuals, companies, society and the planet.
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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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Keywords
Leadership, human resource management, crisis management, change management and communication.
Abstract
Subject area
Leadership, human resource management, crisis management, change management and communication.
Study level/applicability
Executive education; postgraduate; undergraduate.
Case overview
This case study describes the collapse of Satyam, a leading IT industry service provider from India. Satyam went into a crisis mode after revelation of financial fraud by its Chairman. This resulted in a crisis not just for the company, its clients and employees – but it also had the potential to shake up the entire Indian IT industry the world over, by shattering investor and client confidence in the Indian IT sector. The case provides the students with an inside view of the unfolding of events at Satyam and the people challenges that emerge in a crisis scenario. The case outlines reactions from the industry, government, clients and employees as they tried to make sense of a very chaotic situation, and its multi-level ramifications both within India and outside. The case ends with Thallapalli Hari, the Global Head of Marketing and Communication and ex-head of HR, trying to visualise and prioritise a course of action to propose to other members of the leadership team.
Expected learning outcomes
The key aim of this case is to provide a backdrop to the crisis, and also help students put themselves in the role of an HR crisis manager as well as portray the decision making and communication challenges that emerge in chaotic situations. The importance of an immediate and yet strategic response is emphasised and the case is a great starting point to have a discussion on the competencies and skills required in HR to lead under unusual circumstances. This case allows participants to get an in-depth understanding of the collapse of Satyam. The case also illustrates principles of leadership, change management and communication, in particular:
Leadership: The Satyam story is an HR and leadership crisis nightmare come true. What should an HR leader do when you wake up to find your company with a ruined reputation, minimal financial capital, 53,000 employees on the payroll and more than 500 clients with pending deliverables worldwide. Where do you begin? The case illustrates a situation where immediate action is required to stop the tailspin into which the company was heading.
Change management: The situation demanded that change be managed from a chaotic system to a stable system. The big issue though remains as to how one can get a system into a state of stability when everything is changing at the same time. Most change management plans have some stable variables, however in the case of Satyam there were multiple changes taking place simultaneously. A combination of change in leadership, client relationships, employee trust and confidence, market reactions together make for a perfect storm. Dealing with even one of these changes is a challenge for a company. In the case of Satyam, its entire existence was at stake.
Communication: The demands for communicating effectively in a crisis situation are different than communicating under stable systems. The choice of medium, the speed of response, the content all need careful monitoring. Whereas most companies have teams that separately deal with internal and external communication, Satyam provides a unique situation where managing both effectively at the same time was critical to the future of the firm. The stakes for effective communication are much higher under the circumstances. This case can be used in organizational behaviour, human resources and corporate communications modules being taught to under-graduates, post-graduates and for executive education.
Leadership: The Satyam story is an HR and leadership crisis nightmare come true. What should an HR leader do when you wake up to find your company with a ruined reputation, minimal financial capital, 53,000 employees on the payroll and more than 500 clients with pending deliverables worldwide. Where do you begin? The case illustrates a situation where immediate action is required to stop the tailspin into which the company was heading.
Change management: The situation demanded that change be managed from a chaotic system to a stable system. The big issue though remains as to how one can get a system into a state of stability when everything is changing at the same time. Most change management plans have some stable variables, however in the case of Satyam there were multiple changes taking place simultaneously. A combination of change in leadership, client relationships, employee trust and confidence, market reactions together make for a perfect storm. Dealing with even one of these changes is a challenge for a company. In the case of Satyam, its entire existence was at stake.
Communication: The demands for communicating effectively in a crisis situation are different than communicating under stable systems. The choice of medium, the speed of response, the content all need careful monitoring. Whereas most companies have teams that separately deal with internal and external communication, Satyam provides a unique situation where managing both effectively at the same time was critical to the future of the firm. The stakes for effective communication are much higher under the circumstances. This case can be used in organizational behaviour, human resources and corporate communications modules being taught to under-graduates, post-graduates and for executive education.
Supplementary materials
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Kasturi Muniapan, Rosmaini Ahmad, Muhammad Shahar Jusoh, Shaliza Azreen Mustafa and Tan Chan Sin
This paper proposes an assessment method for lean and sustainability (LS) practices for shop-floor workers, designed to evaluate their current practice culture.
Abstract
Purpose
This paper proposes an assessment method for lean and sustainability (LS) practices for shop-floor workers, designed to evaluate their current practice culture.
Design/methodology/approach
The method is developed in five phases: setting predefined indicators, constructing the assessment mechanism, implementing the assessment procedure, analyzing data and delivering results with recommendations. Validation is performed using two worker groups – line supervisors and operators – within the light-emitting diode (LED) manufacturing industry.
Findings
The results showed that workers’ familiarity and understanding of LS practices do not always correspond to their awareness levels. Key recommendations include prioritizing training for critical cases and adapting training approaches to fit the specific knowledge profiles identified.
Research limitations/implications
Firstly, the company should integrate the proposed assessment into an online platform that can automatically generate individual statistical results and priority levels. This reduces the burden of manual work and makes large-scale assessments more practical. Secondly, the study should expand to other shop-floor workers, such as technicians and engineers, to assess their knowledge profiles for future LS development initiatives.
Practical implications
The recommendations provide managers and training departments with guidelines to revise current training approaches. The methodology is validated, enabling the identification and mapping of each worker’s knowledge profile.
Originality/value
This study presents an original assessment method for evaluating the knowledge profiles of shop-floor workers regarding LS practices. To the best of the authors’ knowledge, no prior literature has reported on an assessment method targeting this specific group. The proposed approach supports the decision-making process for better LS practices in the company.
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Chieh-Yu Lin, Cathay Kuo-Tai Kang and Yi-Hui Ho
This study aims to analyze the determinants influencing Chinese manufacturing companies in implementing lean manufacturing (LM).
Abstract
Purpose
This study aims to analyze the determinants influencing Chinese manufacturing companies in implementing lean manufacturing (LM).
Design/methodology/approach
The determinants to be explored in this study consist of technological, organizational and environmental (TOE) dimensions. A questionnaire survey was conducted on Chinese manufacturing companies, and 208 samples were analyzed.
Findings
The findings show that the relative advantage of LM and organizational support have significantly positive effects on Chinese manufacturing firms’ adoption of LM. The complexity of LM, quality of human resources, organizational readiness, customer pressure, international situation, governmental support and environmental uncertainty do not have significant effects.
Originality/value
This paper contributes to the literature by using the TOE model to explore the factors influencing LM adoption in the Chinese manufacturing industry.
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Subhodeep Mukherjee, Ramji Nagariya, Manish Mohan Baral, Bharat Singh Patel, Venkataiah Chittipaka, K. Srinivasa Rao and U.V. Adinarayana Rao
The circular economy is a production and consumption model that encourages people to share, lease, reuse, repair, refurbish and recycle existing materials and products for as long…
Abstract
Purpose
The circular economy is a production and consumption model that encourages people to share, lease, reuse, repair, refurbish and recycle existing materials and products for as long as possible. The blockchain-based circular economy is being used in many industries worldwide, but Indian electronic MSMEs face many problems in adopting a blockchain-based circular economy. The research aims to discover the barriers the electronic MSMEs face in adopting a blockchain-based circular economy and pull back from achieving environmental sustainability in their operations.
Design/methodology/approach
Fifteen barriers are identified from the literature review and finalized with experts' opinions. These barriers are evaluated by using interpretive structural modeling (ISM), MICMAC analysis and fuzzy TOPSIS method.
Findings
Lack of support from distribution channels, lack of traceability mechanism and customer attitudes toward purchasing remanufactured goods are identified as the most critical barriers.
Practical implications
The study will benchmark the electronic MSMEs in achieving environmental sustainability in the blockchain-based circular economy.
Originality/value
It is a study that not only establishes a hierarchical relationship among the barriers of blockchain adoption in Indian electronic MSMEs but also verifies the results with fuzzy TOPSIS method.