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Article
Publication date: 3 May 2021

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…

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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.

Details

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

Keywords

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Article
Publication date: 17 May 2022

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…

547

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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Article
Publication date: 21 November 2023

Deepak Bubber, Gulshan Babber, Shashi   and Rakesh Kumar Jain

This study aims to explore the interrelationships among human-related lean practices, lean production shop floors, process quality, inventory management, operational productivity…

218

Abstract

Purpose

This study aims to explore the interrelationships among human-related lean practices, lean production shop floors, process quality, inventory management, operational productivity and business productivity.

Design/methodology/approach

This study used a cross-sectional survey approach, and quantitative data were collected from 324 Indian auto-component manufacturing firms. Confirmatory factor analysis was used, followed by structural equation modelling techniques for the conceptual model, which incorporated a complete set of 11 hypotheses.

Findings

The results confirmed that human-related lean practices trigger lean production shop floors and improve process quality. Furthermore, the study revealed the positive impact of a lean production shop floor on process quality and inventory management and the positive impact of process quality on both operational and business productivity. Finally, inventory management is of the utmost importance in achieving better operational and business productivity, and operational productivity positively leads to business productivity.

Originality/value

The findings of this study can benefit auto-component manufacturing firms by elucidating the complex relationships between human-related lean practices, lean production shop floors, process quality, inventory management, operational productivity and business productivity. Better knowledge of these relationships will enable firms to enhance efficiency levels, reduce costs and resource wastage and improve their overall performance. This study provides a good understanding of the interplay between lean and quality factors and their influence on inventory management and business performance.

Details

Global Knowledge, Memory and Communication, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 2514-9342

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Article
Publication date: 20 September 2024

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…

98

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.

Details

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

Keywords

Available. Open Access. Open Access
Article
Publication date: 7 May 2024

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…

754

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.

Details

Journal of Responsible Production and Consumption, vol. 1 no. 1
Type: Research Article
ISSN: 2977-0114

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Article
Publication date: 29 November 2024

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.

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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.

Details

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

Keywords

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Article
Publication date: 28 March 2024

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).

180

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.

Details

International Journal of Lean Six Sigma, vol. 15 no. 4
Type: Research Article
ISSN: 2040-4166

Keywords

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Article
Publication date: 5 October 2022

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…

608

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.

Details

Management of Environmental Quality: An International Journal, vol. 34 no. 4
Type: Research Article
ISSN: 1477-7835

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Article
Publication date: 21 April 2022

Narpat Ram Sangwa and Kuldip Singh Sangwan

This paper proposes an integrated value stream mapping (VSM) for a complex assembly line to improve the leanness of a complex automotive component manufacturing organization.

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Abstract

Purpose

This paper proposes an integrated value stream mapping (VSM) for a complex assembly line to improve the leanness of a complex automotive component manufacturing organization.

Design/methodology/approach

This study depicts the application of VSM at the case organization, where top management is concerned about the challenges of higher cycle time and lower productivity. Gemba walks were conducted to establish the concept of “walk the flow, create the flow” along the assembly line. The multi-hierarchical cross-functional team developed the current value stream map to know the “as-is” state. Then, the team analysed the current VSM and proposed the future VSM for the “to-be” state.

Findings

The integrated VSM shows different processes and work cells, various wastes, non-value-added activities, cycle time, uptime and the material and information flows for both products of the assembly line on the same map. The integrated VSM reduced cycle time, non-value-added activities, work in process inventory and improved line efficiency and production per labour hour for both the products, simultaneously.

Research limitations/implications

The limitation of the study is that the study focussed only on the application of VSM for one complex assembly only. Future research may be conducted using the developed integrated VSM approach in other complex production environments.

Practical implications

Managers can identify and reduce system waste by incorporating the concept of integrated VSM in a complex production or assembly environment where two or more products are being manufactured/assembled with low similarity.

Originality/value

The application of VSM for assembly lines is highly challenging because of merging flows, a large number of child parts in the lines and assembly of more than one product on the same line.

Details

The TQM Journal, vol. 35 no. 4
Type: Research Article
ISSN: 1754-2731

Keywords

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Article
Publication date: 18 July 2022

V. Vaishnavi and M. Suresh

Environmental sustainability (ES) is an increasing tendency in the healthcare industry as it seeks to enhance the environmental friendliness and reduces waste in operations to…

695

Abstract

Purpose

Environmental sustainability (ES) is an increasing tendency in the healthcare industry as it seeks to enhance the environmental friendliness and reduces waste in operations to save money. The objective of research article is to identify the factors that contribute to improving the performance of ES in hospitals. Understanding the factors that contribute to the improvement of healthcare services may be helpful for practitioners, who need to address and implement an effective framework to enable an environment-friendly practice in hospitals.

Design/methodology/approach

The current study utilised the technique called total interpretive structural modelling (TISM) to identify the factors and understand the interconnection between the identified factors. A literature review revealed 12 factors, which were then refined with the input of hospital experts. Based on a questionnaire survey, a planned interview is conducted in chosen Indian hospitals. The matrix impact cross multiplication applied to classification (MICMAC) study employs dependency and driving power to identify the hierarchical relationship between the detected factors.

Findings

Green building initiatives, water consumption, resource usage, and renewable energy were identified as key factors in the study. Other factors such as staff behaviour, procurement of goods and management of hazardous substance would be influenced by these fundamental components. With the implementation of green initiatives in the hospital, ES is primarily used to reduce the excessive use of scarce resources.

Practical implications

The ES programme begins at the hospital grounds, with awareness and specific training provided to all personnel, including doctors, nurses, and managers at all levels. The training programme is intended to raise awareness; sessions are divided into targeted groups; a new organisational structure is created; and a consultant agent is hired to commence ES.

Originality/value

Existing literature has focussed mostly on ES factors such as carbon emissions, water conservation, and effective waste disposal, while ignoring organisational viewpoints and their interrelationships. As a result, the current study used TISM to show the relationship between various organisational and environmental perspective components in order to comprehend the reasoning behind improving performance.

Details

Management of Environmental Quality: An International Journal, vol. 34 no. 1
Type: Research Article
ISSN: 1477-7835

Keywords

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