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"Lean manufacturing."
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Industry 4.0 implies lean manufacturing: research activities in industry 4.0 function as enablers for lean manufacturing
Purpose: Lean Manufacturing is widely regarded as a potential methodology to improve
productivity and decrease costs in manufacturing organisations. The success of lean
manufacturing demands consistent and conscious efforts from the organisation, and has to
overcome several hindrances. Industry 4.0 makes a factory smart by applying advanced
information and communication systems and future-oriented technologies. This paper analyses
the incompletely perceived link between Industry 4.0 and lean manufacturing, and investigates
whether Industry 4.0 is capable of implementing lean. Executing Industry 4.0 is a cost-intensive
operation, and is met with reluctance from several manufacturers. This research also provides an
important insight into manufacturers’ dilemma as to whether they can commit into Industry 4.0,
considering the investment required and unperceived benefits.
Design/methodology/approach: Lean manufacturing is first defined and different dimensions
of lean are presented. Then Industry 4.0 is defined followed by representing its current status in
Germany. The barriers for implementation of lean are analysed from the perspective of
integration of resources. Literatures associated with Industry 4.0 are studied and suitable solution
principles are identified to solve the above mentioned barriers of implementing lean.
Findings: It is identified that researches and publications in the field of Industry 4.0 held answers
to overcome the barriers of implementation of lean manufacturing. These potential solution principles prove the hypothesis that Industry 4.0 is indeed capable of implementing lean. It
uncovers the fact that committing into Industry 4.0 makes a factory lean besides being smart.
Originality/value: Individual researches have been done in various technologies allied with
Industry 4.0, but the potential to execute lean manufacturing was not completely perceived. This
paper bridges the gap between these two realms, and identifies exactly which aspects of Industry
4.0 contribute towards respective dimensions of lean manufacturing.
Journal Article
Save it for a rainy day! Lean strategies for cost saving: The role of Lean maturity
Purpose: This study investigates the effect of lean implementation on production cost reduction and the moderating role of lean manufacturing maturity.Design/methodology/approach: This study employed a cross-sectional survey, of which the samples were drawn using a cluster sampling procedure from 151 middle and top-level management of medium and large manufacturing companies gathered from the Federation of Manufacturers Malaysia (FMM). Data were analyzed using the PLS-SEM approach through SmartPLS4 software.Findings: The result revealed that lean implementation does not leverage production cost reduction as the lean journey requires long-term orientation, which finally leads to valid cost reduction. The moderating role of lean manufacturing maturity was significant and positive in the relationship between lean manufacturing implementation and production cost reduction.Research limitations/implications: Future research should include longitudinal settings as this study is cross-sectional, and future research might put the present model to the test in multiple industries and regions, including a cross-country comparison to improve the generalizability of the findings. Additionally, further studies could extend this study using a mixed-method approach.Practical implications: By offering a holistic perspective, this study expands the existing literature, contributes to knowledge of integrated lean implementation and supports the management in planning their path towards cost-cutting performance.Originality/value: This study answers the inconclusive finding between lean implementation and operational performance in terms of production cost reduction. The study contributes to the body of knowledge and, most importantly, to the practitioners in planning their lean journey.
Journal Article
Lean manufacturing implementation: bibliometric analysis 2007–2018
In order to preserve competitiveness in their markets, organizations seek incessantly tools to help them manage their activities. To identify scientific production related to lean manufacturing implementation in organizations. This study was undertaken through bibliometric analysis using metadata extracted from two different scientific databases: Web of Science and Scopus, in the period from 2007 to 2018. The literature trend lies in the barriers faced by lean manufacturing implementation, in framework development to support implementation, and in model building to evaluate what has been done. The contribution of this work is in the opportunity to suggest of a knowledge repository to support lean manufacturing projects. The authors’ main discussions are related to lean manufacturing models, and the lack of sharing experiences acquired by employees during the deployment process.
Journal Article
Beyond lean : a revised framework of leadership and continuous improvement
\"This book by Peter Bâendek presents a strong case against the current practice of business operations improvement, based on numerous studies from the business world as well as insights from the most prestigious authors of the last fifty years. The author contests the applicability and indeed the relevance of the Toyota Production System and its spin-offs to the Western context, claiming that a revised approach is much better suited to taking our specific cultural conditions into account, while also combining increased transparency, speed, and sustainability of change with a robust value-creating capability. Dr. Bâendek argues that this approach can have a far-reaching impact on corporate cultures by offering an all-encompassing learning system, one that provides a more coherent and actionable continuous improvement strategy than conventional approaches. The book offers an important guide to rethinking operations management, both in academia and business practice.\"--Page 4 of cover.
Book
Developing and validating lean manufacturing constructs: an SEM approach
Purpose
The purpose of this paper is to provide valid and reliable constructs for lean manufacturing (LM) for assessing its implementation level in order to target areas of improvement.
Design/methodology/approach
Based on an extensive review on LM literature and content validity assessment from practitioners and academicians, nine LM constructs were identified. Measurement items for each construct were developed to become a complete questionnaire. The questionnaire booklets were distributed to large and discrete manufacturing companies in Indonesia. Out of 1,000 survey questionnaires sent, 236 usable responses were returned giving response rate of 23.60 percent. Subsequently, an empirical assessment on the constructs was done by using structural equation modeling approach.
Findings
The study identified the valid and reliable LM constructs, consisting of nine LM constructs and 64 measurement items. The study found that all the constructs are complementary and mutually supportive with each other. Indeed, it suggests the holistic implementation of all the LM practices.
Research limitations/implications
Owing the time and resource constraint, this study only involved large and discrete process manufacturing industries in Indonesia. Hence, the generalization of the result is slightly limited. More studies in several different contexts are required.
Practical implications
This study provided a valuable tool for researchers for gaining deeper understanding regarding the LM and its implementation. For practitioners, it is useful to evaluate the degree of LM employment in their companies, to target area of improvement, as well as to take possible actions in attempting to enhance the organizational performance. More importantly, practitioners should adopt all the LM practices in a holistic manner.
Originality/value
This study is the first attempt to develop LM constructs for evaluating the LM implementation in Indonesia.
Journal Article
Lean manufacturing implementation: an assessment method with regards to socio-technical and ergonomics practices adoption
The implementation of lean manufacturing (LM) means a systematic approach of various management methods and practices, which may influence individuals’ job content and the quality of work. However, research related to socio-technical and ergonomics (SE) factors has for a long time solely focused on regular production work to a large extent. This study aims to assess the relationship between LM and SE practices in companies undergoing a lean implementation. The proposed method comprises a combination of techniques that allow the identification of deficiencies related to the adoption of LM practices that may support SE practices implementation, indicating a prioritization of improvements opportunities to better sustain them. Further, through the establishment of the degree of criticality of LM practices, our outcomes allow to identify implementation gaps in the lean process that are highly related with the current status of socio-technical and ergonomics improvements in the company, anticipating problems and developing the practices that converge to them.
Journal Article