Application of lean practices in small and medium-sized food enterprises

2013 ◽  
Vol 116 (1) ◽  
pp. 125-141 ◽  
Author(s):  
Manoj Dora ◽  
Dirk Van Goubergen ◽  
Maneesh Kumar ◽  
Adrienn Molnar ◽  
Xavier Gellynck
Keyword(s):  
Food Processing ◽  
Lean Manufacturing ◽  
Raw Materials ◽  
Current Status ◽  
Food Sector ◽  
Statistical Process ◽  
Content Type ◽  
Lean Practices ◽  
The Status ◽  
Manufacturing Techniques

Purpose – Recent literature emphasizes the application of lean manufacturing practices to food processing industries in order to improve operational efficiency and productivity. Only a very limited number of studies have focused on the implementation of lean manufacturing practices within small and medium-sized enterprises (SMEs) operating in the food sector. The majority of these studies used the case study method and concentrated on individual lean manufacturing techniques geared towards resolving efficiency issues. This paper aims to analyze the status of the lean manufacturing practices and their benefits and barriers among European food processing SMEs. Design/methodology/approach – A structured questionnaire was developed to collect data. A total of 35 SMEs' representatives, mostly CEOs and operations managers, participated in the survey. The study investigated the role of two control variables in lean implementation: size of the company and country of origin. Findings – The findings show that lean manufacturing practice deployment in food processing SMEs is generally low and still evolving. However, some lean manufacturing practices are more prevalent than others; e.g. flow, pull and statistical process control are not widely used by the food processing SMEs, whereas total productive maintenance, employee involvement, and customer association are more widespread. The key barriers encountered by food SMEs in the implementation of lean manufacturing practices result from the special characteristics of the food sector, such as highly perishable products, complicated processing, extremely variable raw materials, recipes and unpredictable demand. In addition, lack of knowledge and resources makes it difficult for food processing SMEs to embark on the lean journey. Originality/value – The gap in the literature regarding the application of lean manufacturing in the food sector is identified and addressed in this study. The originality of this paper lies in analyzing the current status of the use of lean manufacturing practices among food SMEs in Europe and identifying potential barriers.

Structural equation modeling of lean manufacturing practices in a developing country context

2019 ◽  
Vol 30 (1) ◽  
pp. 122-145 ◽  
Author(s):  
Fayiz Dahash Shrafat ◽  
Mohammad Ismail
Keyword(s):  
Structural Equation Modeling ◽  
Lean Manufacturing ◽  
Structural Equation ◽  
Statistical Processing ◽  
Equation Modeling ◽  
Significant Implication ◽  
Sampling Frame ◽  
Statistical Process ◽  
Content Type ◽  
Lean Practices

PurposeThe purpose of this paper is to empirically examine lean manufacturing (LM) practices and to quantify their impact on business performance (BP), with particular emphasis on the mediating role of operational performance (OP) in deriving the BP benefits commonly linked with LM. It also seeks to identify those lean practices most appropriate for application.Design/methodology/approachEmpirical data on LM practices were collected using a structured survey questionnaire. The sampling frame was Jordanian companies registered and listed by the Amman Chamber of Commerce. In total, 500 questionnaires were distributed among 300 companies and a total of 249 completed questionnaires were eligible for statistical processing, a response rate of 49.8 percent. Invalid questionnaires were eliminated, leaving 228 usable. The theoretical relations were tested by structural equation modeling.FindingsAlthough the results of the statistical analysis indicate a positive and significant impact of implementing LM practices on both OP and BP, they also show that the various LM practices did not receive equal recognition among the organizations surveyed. The most commonly adopted lean principles were found to be total preventive maintenance, statistical process control and housekeeping 5S.Research limitations/implicationsOther lean practices have not been considered as a dimension in this study. However, it opens new avenues of investigation relevant to lean practices.Practical implicationsThe most significant implication of the study is that managers in manufacturing firms should place more emphasis on LM practices when developing strategies for leveraging performance. The study shows that the LM approach contributes to BP when LM practices are simultaneously implemented.Originality/valueThe originality of this study lies in the new context in which it was conducted. The study adds value by investigating the implementation of LM practices which have been transferred from developed to developing countries and by empirically examining their impact on key performance indicators within the Jordanian manufacturing sector.

Lean implementation in Indian process industries – some empirical evidence

2015 ◽  
Vol 26 (1) ◽  
pp. 131-160 ◽  
Author(s):  
Avinash Panwar ◽  
Rakesh Jain ◽  
A.P.S. Rathore
Keyword(s):  
Lean Manufacturing ◽  
Design Methodology ◽  
Statistical Tests ◽  
Empirical Studies ◽  
Process Industries ◽  
Lean Implementation ◽  
Content Type ◽  
Performance Improvements ◽  
Lean Practices ◽  
The Status

Purpose – In the present era of intense competition, industries are adopting lean manufacturing for successful survival. The concept of lean manufacturing is new for Indian process industries. The purpose of this paper is to investigate the status of lean manufacturing in Indian process industries in terms of lean practices, reasons and challenges of implementing lean manufacturing. Design/methodology/approach – A survey was carried out to assess the level of lean implementation in Indian process industries. Statistical tests were conducted to assess the significant lean practices, reasons and challenges of implementing lean in Indian process industries. Findings – It is observed that the level of implementation of lean manufacturing in Indian process industries is still low. Results indicate that Indian process industries those who have implemented lean found lean to be very useful to reduce wastes and to increase quality. Major lean practices being implemented by Indian process industries are primarily those which are related to waste elimination or improvement in quality. Indian process industries found that important challenges to implement lean are to produce in small batches, to arrange for lean experts and to impart training to employees. Research limitations/implications – In the present study, the sample size is small and hence, the findings should be generalized cautiously. Although the study indicates that lean can be very useful if implemented in Indian process industries but further empirical studies are required to quantify performance improvements through adoption of lean. Originality/value – The paper explores status of lean adoption in Indian process industries. Considering the unique characteristics of process industries, the present research would be helpful for making strategies to implement lean in process industry setups.

Lean manufacturing implementation in regions with scarce resources

2019 ◽  
Vol 58 (2) ◽  
pp. 313-343 ◽  
Author(s):  
Léony Luis Lopes Negrão ◽  
Moacir Godinho Filho ◽  
Gilberto Miller Devós Ganga ◽  
Sunil Chopra ◽  
Matthias Thürer ◽  
...  
Keyword(s):  
Lean Manufacturing ◽  
Technological Development ◽  
Manufacturing Companies ◽  
Statistical Process ◽  
Lean Implementation ◽  
Content Type ◽  
Scarce Resources ◽  
Lean Practices ◽  
Cultural Research ◽  
Strategic Context

Purpose The purpose of this paper is to explore the adoption of lean practices by manufacturing companies in regions of low economic and technological development and to compare findings with previous studies from more developed regions highlighting important contextual differences. The paper uses the contingency theory to explore how contextual variables and scarce resources influence the adoption of lean practices. Design/methodology/approach A survey of 233 manufacturing firms was conducted in the State of Pará in the Amazon Region of Brazil. Findings The results demonstrate that six internal lean practices (single minute exchange of dies, human resource management, continuous flow, total productive maintenance, pull and statistical process control) and two external lean practices (supplier feedback and customer involvement) are implemented. However, the two external lean practices of just-in-time delivery by suppliers and supplier development were not implemented. Furthermore, from the 36 operating items comprised in eight lean practices that are being used, 13 were not implemented. As such, compared to developed regions, there is evidence for a more fragmented implementation in less developed regions. The results reveal empirical evidence explained by the contingency perspective, such as national, geographical, strategic context and culture. Originality/value There is broad evidence on lean implementation in developed and developing countries in the literature. However, little is known about lean implementation in poorer regions of developing counties. This is one of the first studies mapping lean implementation in a region with low economic and technological development. This has important implications for research and practice, especially to cross-country/cultural research on operation management.

Status of lean manufacturing practices in Indian industries and government initiatives

2014 ◽  
Vol 25 (5) ◽  
pp. 655-675 ◽  
Author(s):  
S.J. Thanki ◽  
Jitesh Thakkar
Keyword(s):  
Lean Manufacturing ◽  
Hierarchical Cluster ◽  
Current Status ◽  
Eastern Region ◽  
Process Technology ◽  
Lean Implementation ◽  
Content Type ◽  
Lean Practices ◽  
Lean Assessment ◽  
Indian Industries

Purpose – The purpose of this paper is to report a pilot study on lean awareness and implementation using the survey data collected from about 32 industries situated in western and eastern region of India. Design/methodology/approach – A survey instrument containing 45 statements was designed to assess respondents’ attitude and awareness toward lean practices and to explore the level of lean implementation in the organization. The instrument was distributed personally or through mail to the employees of 32 industries and they were supported for any query about the questions. Descriptive statistical analysis, hierarchical cluster analysis and ANOVA were used to analyze the data with SPSS statistical software. Findings – The research uncovers the fact that the current status of lean implementation and awareness in Indian industries is not so encouraging and the reason for that is, the human-related issues are not tackled properly. Quality and process technology, are the two key areas where industries are indicating inadequate efforts and poor insight. Research limitations/implications – The study conducted was limited to 32 industries situated in the eastern and western region of India. The data collected for few industries rely on only one respondent. Practical implications – The study identifies the lean implementation status based on nine lean assessment key areas and uncovers the major roadblocks for lean practices in Indian industries. It provides key insights to lean practicing industries and lean practitioner about the major barriers and key areas for the improvement. Originality/value – The paper reports comprehensive insights on current awareness and implementation of lean manufacturing (LM) in India. It also highlights the initiatives taken by Government of India to increase the competitiveness of the Indian industries, specifically of manufacturing sector, through the adoption of LM techniques. This would provide a platform for carrying out a detailed research in LM in Indian context.

Exploring the importance of cultural collectivism on the efficacy of lean practices

2015 ◽  
Vol 35 (3) ◽  
pp. 370-391 ◽  
Author(s):  
Frank Wiengarten ◽  
Cristina Gimenez ◽  
Brian Fynes ◽  
Kasra Ferdows
Keyword(s):  
Lean Manufacturing ◽  
Negative Impact ◽  
National Level ◽  
Organisational Culture ◽  
Cultural Dimension ◽  
Content Type ◽  
Lean Practices ◽  
Individualistic Culture ◽  
Cultural Components ◽  
Organisational Level

Purpose – The purpose of this paper is to assess the influence of cultural collectivism on the efficacy of lean practices. Furthermore, this study assesses whether or not potential cultural disadvantages related to the level of individualism at the national level can be compensated for at the organisational culture level. Design/methodology/approach – Hofstede’s cultural dimension of individualism is used to test whether practicing a collectivistic culture at the organisational level can fully compensate for the potential disadvantages of being geographically situated in an individualistic culture when practicing lean manufacturing. Findings – Results suggest that cultural collectivism at the national and organisational level have a significant impact on the efficacy of lean practices. Furthermore, the negative impact of being situated in an individualistic country cannot be fully compensated for through practicing a collectivistic organisational culture when practicing lean. Originality/value – This study represents a comprehensive attempt to simultaneously assess the collectivism cultural components of lean practices at the national as well as at the organisational level.

scholarly journals Burden or blessing in disguise: interactions in supply chain complexity

2018 ◽  
Vol 38 (2) ◽  
pp. 314-332 ◽  
Author(s):  
Hendryk Dittfeld ◽  
Kirstin Scholten ◽  
Dirk Pieter Van Donk
Keyword(s):  
Supply Chain ◽  
Food Processing ◽  
Raw Materials ◽  
Structured Interviews ◽  
Food Processing Industry ◽  
Dynamic Complexity ◽  
Processing Industry ◽  
Case Study Methodology ◽  
Content Type ◽  
Different Types

Purpose While systems theory explicitly considers interactions as part of a system’s complexity, supply chain complexity (SCC) is mostly conceptualized and measured as a linear summation of several aspects. The purpose of this paper is to challenge the general understanding by explicitly investigating interactions between and across different types (detail and dynamic) and levels (plant, supply chain, environment) of SCC. Design/methodology/approach An exploratory multiple case study methodology is adopted drawing on in-depth semi-structured interviews with respondents from eight manufacturing plants in the food processing industry. Findings On the one hand, it is found that different types add and increase overall SCC. On the other hand, the study also shows the opposite: interactions between detail and dynamic complexity can reduce the overall SCC experienced. Additionally, the findings highlight the specific food processing characteristics such as the variability of quality and quantity of raw materials that underlie interactions between types and levels of SCC. Originality/value This study adds to theory by empirically showing that interactions across and between types and levels do not automatically increase, but might also reduce SCC. As such, the findings contribute new detail to the concept of SCC: aspects of complexity do not necessarily add up linearly. Additionally, this study is one of the first to demonstrate how specific contextual aspects from the food processing industry relate to SCC.

Comparative analysis of ranking the lean supply chain enablers: An AHP, BWM and fuzzy SWARA based approach

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Hemant Sharma ◽  
Nagendra Sohani ◽  
Ashish Yadav
Keyword(s):  
Supply Chain ◽  
Literature Review ◽  
Lean Manufacturing ◽  
Production Systems ◽  
Initial Step ◽  
Content Type ◽  
Lean Practices ◽  
Manufacturing Organization ◽  
Good Productivity ◽  
Lean Supply Chain

PurposeIn the recent scenario, there has been an increasing trend toward lean practices and implementation in production systems for the improvement of an organization’s performance as its basic nature is to eliminate the wastes. The increasing interest of customers in customized products and the fulfillment of customers’ demand with good productivity and efficiency within time are the challenges for the manufacturing organization; that is why adopting lean manufacturing concept is very crucial in the current scenario.Design/methodology/approachIn this paper, the authors considered three different methodologies for fulfilling the objective of our research. The analytical hierarchy process, best–worst method and fuzzy step-wise weight assessment ratio analysis are the three methods employed for weighting all the enablers and finding the priority among them and their final rankings.FindingsFurther, the best results among these methodologies could be used to analyze their interrelationships for successful lean supply chain management implementation in an organization. In this paper, 35 key enablers were identified after the rigorous analysis of literature review and the opinion of a group of experts consisting of academicians, practitioners and consultants. Thereafter, the brainstorming sessions were conducted to finalize 28 lean supply chain enablers (LSCEs).Practical implicationsFor lean manufacturing practitioners, the result of this study can be beneficial where the manufacturer is required to increase efficiency and reduce cost and wastage of resources in the lean manufacturing process.Originality/valueThis paper is the first of the research papers that considered deep literature review of identified LSCEs as the initial step, followed by finding the best priority weightage and developing the ranking of various lean enablers of supply chain with the help of various methodologies.

Lean manufacturing practices and performance: the role of social and technical factors

2019 ◽  
Vol 37 (5) ◽  
pp. 732-754 ◽  
Author(s):  
Saumyaranjan Sahoo
Keyword(s):  
Lean Manufacturing ◽  
Business Performance ◽  
Manufacturing Systems ◽  
Equation Modeling ◽  
Performance Parameters ◽  
Content Type ◽  
Lean Practices ◽  
The Social ◽  
And Performance ◽  
The Relationship

Purpose Modern manufacturing systems require tools and techniques that take cognizance of the social (concerning people and relations) as well as the technical environment. The purpose of this paper is to explore the relationship between the social and technical aspects of lean manufacturing practices and their effects on business performance outcomes. Design/methodology/approach The hypothesized relationships for this study are tested with data collected from 148 Indian manufacturing firms by using SPSS and AMOS statistical software. Findings The analysis of the study was conducted using structural equation modeling (SEM) technique, which indicated that both “soft” and “hard” lean practices are positively related to business performance parameters. The findings also demonstrated that “hard” lean practices fully mediate the relationship between “soft” lean practices and business performance parameters. Research limitations/implications There are some limitations of this study. Although a cross-sectional survey has been applied, the research does not permit us to account for the lag between implementation and performance. It also brings the opinion of a limited number of Indian experts about lean manufacturing systems; hence, the sample size could be increased and the nationality of the respondent could be expanded for future research. Practical implications The paper would be of interest to Lean practitioners, and the results of this study can be used in organizations to put a focus on social-cultural changes while applying lean technical tools when it comes to practices as well as importance. Originality/value This paper extends theoretical contribution in production and operations management literature, highlighting how social and technical practices have to interact to enable a successful lean manufacturing implementation.

The relationships among transformational leadership, sustainable leadership, lean manufacturing and sustainability performance in Thai SMEs manufacturing industry

2019 ◽  
Vol 36 (6) ◽  
pp. 1014-1036 ◽  
Author(s):  
Piyachat Burawat
Keyword(s):  
Transformational Leadership ◽  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Structural Model ◽  
Participant Observation ◽  
Sustainable Leadership ◽  
Content Type ◽  
Sustainability Performance ◽  
Lean Practices ◽  
Depth Interview

Purpose The purpose of this paper is to examine the structural relationship model among transformational leadership, sustainable leadership (SL), lean manufacturing practices and sustainability performance. Design/methodology/approach The data were collected from the middle and senior managers working in small and medium enterprises of Thai manufacturing industry. Regarding the quantitative approach, the data were collected by means of survey from 598 respondents from 374 companies. Qualitative data were collected from 40 participants by participant observation, non-participant observation and in-depth interview. Findings The model reported that lean manufacturing has a partial mediate effect on the relationship between transformational leadership and sustainability performance, and between SL and sustainability performance. The structural model is different in automotive and nonautomotive companies, and the structural model is different among the companies which implemented lean program for less than five years and above five years. The data from in-depth interview informed that lean practices are appropriate for automotive industry though with less implementation in other industries. Firms pay most attention on customer involvement with some attention on employee and supplier involvement. Managers give advices and exchange ideas with their followers rather than inspiring and giving opportunities to make decision. Research limitations/implications The findings may also enable Thai managers to realize that lean practices are appropriate for any industry. The first thing to do before launching lean program to all process is that the company should buy-in the understanding of managers about lean concept and implementation. Willingness with well understanding and realizing importance of lean program will lead to superior results, especially operational, economic and sustainable performance. Originality/value The reliability and validity measurements confirmed that both SL and environmental and social performance are appropriate for manufacturing industries. This study provides evidence of the positive relationship between SL and lean manufacturing, lean manufacturing and sustainability performance, as well as the partial mediate effect of lean manufacturing on the relationship between SL and sustainability performance, which are the additional contributions to research in academic field. The results confirmed the positive relationship between transformational leadership and lean manufacturing. The results reported that there is difference of lean practices between automotive and nonautomotive companies, and between companies which implemented lean program less than five years and above five years. The structural relationship result reported that transformational leadership has effects on lean manufacturing whereas SL has no effect on lean manufacturing, which asserted the previous study in which one leadership model is more appropriate for success within lean implementations.

EEU, WTO pose problems to Kazakhstani agri-food sector

2015 ◽  
Keyword(s):  
Food Processing ◽  
Agricultural Sector ◽  
Food Sector ◽  
Social Unrest ◽  
Content Type ◽  
Food And Agriculture ◽  
Eurasian Economic Union ◽  
Economic Union ◽  
State Subsidies ◽  
Agriculture And Food

Subject Outlook for the food and agriculture sectors. Significance Speaking in Astana in June, Kazakhstani President Nursultan Nazarbayev said the country's agricultural sector was expected to benefit from 16 billion dollars in foreign direct investment (FDI) by 2021. This is foreseen in the 'Agribusiness-2020' strategic programme, which was adopted in February 2013. Agriculture and food processing remain key areas of Kazakhstan's economy, the former having traditionally absorbed a large amount of state subsidies. However, their future looks uncertain in light of Kazakhstan's accession to the WTO and its membership in the Eurasian Economic Union (EEU). Impacts Flooding the Kazakhstani market with cheap imports may lead to mass bankruptcies in domestic agri-business and spark social unrest. Corruption remains a serious obstacle to the efficient use of government-allocated funds to support agriculture and food processing. Investor interest in Kazakhstan's agriculture will remain limited because of internal constraints.

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