Assessing lean implementation and benefits within Indian automotive component manufacturing SMEs

2020 ◽  
Vol 27 (3) ◽  
pp. 1042-1084 ◽  
Author(s):  
Saumyaranjan Sahoo
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Management Practices ◽  
Manufacturing Sector ◽  
Shop Floor ◽  
Automotive Component ◽  
Content Type ◽  
Study Approach ◽  
The Status ◽  
Component Manufacturing

PurposeThe purpose of this paper is to investigate the status of lean manufacturing in Indian automotive sector, component manufacturing industries in terms of lean adoption, benefits, motivation, and challenges of implementing lean manufacturing practices.Design/methodology/approachThe research objectives were achieved by conducting a qualitative multicase study approach. Fourteen Indian automotive component manufacturing small and medium-sized enterprises (SMEs) were chosen based on their different product offerings as well as differing approaches to the introduction and implementation of lean initiatives. Data were collected through in-depth, semistructured interviews supported by shop-floor observations.FindingsThe findings from the present study suggest that some of the participating automotive component manufacturing SMEs have a relatively good understanding of lean concepts and philosophy. However, there is room for further improvement for most SMEs. Major top five lean practices being implemented were found to be cellular manufacturing, total productive maintenance, 5S, work standardization, and quality management practices. Also, leadership and organizational culture were found to be crucial factors for the success of lean manufacturing.Research limitations/implicationsThe fact that the data collected for the research study is based on subjective business evidence obtained from company representatives comprises the main limitation of the present study. So, the results should be considered with caution, as far as the lean adoption in Indian automotive component manufacturing sector is concerned.Practical implicationsBased on the present study, suggestions can be made regarding the successful adoption of lean principles, not only for the participating SMEs but also for the whole of the automotive component manufacturing sector. More specifically, by determining the strength and weakness of automotive component manufacturing SME's effort to adopt lean, suitable managerial initiatives can be undertaken by these companies as well as the whole sector to fully adopt lean and derive the respective benefits.Originality/valueThis paper explores the status of lean adoption in Indian automotive component manufacturing SMEs. Considering the unique characteristics of the automotive component manufacturing industry, the present research would be helpful for making strategies to implement lean in automotive component manufacturing industry setups.

Sustainability assessment in the manufacturing industry: a review of recent studies

2018 ◽  
Vol 25 (8) ◽  
pp. 3162-3179 ◽  
Author(s):  
Shamraiz Ahmad ◽  
Kuan Yew Wong
Keyword(s):  
Manufacturing Industry ◽  
Sustainability Assessment ◽  
Manufacturing Sector ◽  
Social Indicators ◽  
Sustainable Manufacturing ◽  
Manufacturing Industries ◽  
Bottom Line ◽  
Content Type ◽  
The Status ◽  
Different Levels

Purpose The purpose of this paper is to review and analyze the recent sustainability assessment studies in the manufacturing industry from the triple-bottom-line (TBL) perspective. This paper aims to depict the status quo of practical sustainability assessment, summarize the different levels and boundaries of evaluation, and highlight the difficulties and further improvements needed to make the assessment more effective in the manufacturing industry. Design/methodology/approach Four keywords, namely, sustainability assessment, sustainable manufacturing, TBL and green production, were used to explore and find the relevant articles. First, this paper systematically reviewed the studies and analyzed the different levels and boundaries of sustainability assessment. Following this, the reviewed studies were critically discussed along with their merits and shortcomings. Findings The review showed that most of the sustainability assessment studies were conducted on product, company and process levels in the manufacturing industry. Nevertheless, there is still a need to focus more on plant and process level assessments to achieve the TBL objectives. Environmental assessment is comparatively matured in manufacturing industries. However, from the economic and social viewpoints, only cost analysis and workers’ safety, respectively, were considered in most of the studies. The economic and social indicators need to be more inclusive and should be validated and standardized for manufacturing industries. Originality/value Unlike previous sustainability assessment reviews in manufacturing industries which were mostly based on life cycle assessment, this paper has included environmental, social and economic aspects in one comprehensive review and focused on recent studies published from 2010 to 2017. This paper has explored the recent sustainability assessment trends and provided insights into the development of sustainability assessment in the manufacturing sector.

An investigation into manufacturing performance achievements accrued by Indian manufacturing organization through strategic 5S practices

2018 ◽  
Vol 67 (4) ◽  
pp. 754-787 ◽  
Author(s):  
Jugraj Singh Randhawa ◽  
Inderpreet Singh Ahuja
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Service Industry ◽  
Manufacturing Sector ◽  
Successful Implementation ◽  
Automotive Manufacturing ◽  
Content Type ◽  
Manufacturing Performance ◽  
Improvement Programs ◽  
Manufacturing Organization

Purpose The purpose of this paper is to evaluate the quantitative and qualitative benefits accrued by an Indian automotive parts industry through strategic 5S implementation initiatives. Design/methodology/approach The study involves evaluation of steps involved in systematic implementation of 5S program methodology in an automotive manufacturing organization and investigation of achievements accrued by the industry through the successful implementation of 5S program. Findings The empirical results of the study have revealed that effective practice of 5S program brings considerable level of improvements in the quality, production, cost optimizations, employee’s morale values and work culture in the manufacturing industry. The industry accrued both tangible and non-tangible benefits through the holistic adoption of 5S principals. 5S principals have been envisioned to further support other quality improvement programs like lean manufacturing initiatives of the organizations. Research limitations/implications The limitation of the study is that this research has been carried out in only manufacturing industry while similar study will be conducted in the service industry also. Originality/value Global competition in the manufacturing sector has provided necessary impetus for manufacturing organizations for affecting continuous improvements in manufacturing performance for achieving sustainability and profitability in the competitive market. 5S implementation is the fundamental tool for the overall achievements in both quantitative and qualitative performance enhancements in the manufacturing as well as service organizations.

An empirical study for implementation of lean principles in Indian manufacturing industry

2016 ◽  
Vol 23 (1) ◽  
pp. 183-207 ◽  
Author(s):  
Naga Vamsi Krishna Jasti ◽  
Rambabu Kodali
Keyword(s):  
Customer Satisfaction ◽  
Manufacturing Industry ◽  
Manufacturing Industries ◽  
Shop Floor ◽  
Survey Questionnaire ◽  
Content Type ◽  
Empirical Survey ◽  
Manufacturing Organizations ◽  
The Status ◽  
Research Studies

Purpose – Lean manufacturing (LM) principles are one of the alternatives to improve manufacturing productivity, quality and customer satisfaction in Indian manufacturing industry. The purpose of this paper is to find the implementation status of LM principles across Indian manufacturing organizations through the empirical survey methodology. Design/methodology/approach – The survey questionnaire was developed based upon literature review conducted on LM and also considered experts suggestion in the field of LM. The survey questionnaire was sent to 753 manufacturing organization located in India. The respondent organization details have gathered from the list of Confederation of Indian Industries directory for the year 2011.The selected respondents were production managers, quality managers, sales managers, maintenance managers, CEOs of the organization. The empirical survey collected 180 filled survey questionnaires from Indian manufacturing industries. Findings – The study clearly identified that many manufacturing organizations were in initial transition stage and concentrating mostly in-plant operations instead of collaboration in all levels of business with suppliers and customers. The present study found that drivers for implementation of LM were customer satisfaction and organizational continuous improvement program. The present study also found that barriers to implement LM principles were employee resistance, implementing few elements of LM principles instead of the complete package of LM framework, budget constraints and lack of understanding of LM principles to shop floor managers. Finally the study concluded that Indian manufacturing organizations have to conduct continuous learning programmed to improve understanding of LM principles as well as to maintain their motivation level in apex point. The study also suggested that a systematic LM framework is needs to Indian manufacturing organizations, which will act as clear cut guiding torch to the organization managers to implement LM principles across organization. Research limitations/implications – The sample size of the present study was moderate number than previous studies. However the study only concentrated on manufacturing organizations across India. The results of the present study cannot generalize across all the sectors of Indian organizations. Originality/value – The concept of LM was very popular among developed and developing countries in the world. Many research studies were performed across world to find the status of LM implementation in their countries. Very few research studies reported the status of LM implementation in Indian manufacturing industries and those studies also with limited focus of the status of LM implementation. Hence the study presented details status of LM principles implementation in Indian manufacturing industries.

Analysis of preferred customer enablers from supplier’s perspective

2016 ◽  
Vol 22 (6) ◽  
pp. 1170-1191 ◽  
Author(s):  
Sunil Kumar C.V. ◽  
Srikanta Routroy
Keyword(s):  
Manufacturing Industry ◽  
Statistical Significance ◽  
Common Interest ◽  
Business Practices ◽  
Supplier Relationships ◽  
Automotive Component ◽  
Content Type ◽  
Structural Relationships ◽  
Component Manufacturing ◽  
The Right

Purpose The purpose of this paper is to identify, rank, classify and establish the structural relationships between the preferred customer enablers (PCEs). This analysis would assist a manufacturer in selectively exercising the PCEs and effectively run-through the concept of reverse marketing in the buyer-supplier relationships. Design/methodology/approach In the current study, the interpretive structure modelling and Fuzzy Matriced’ Impacts Croisés Appliquée á un Classement methods are used to analyze and structurally relate the PCEs for Indian automotive component manufacturing industry. Furthermore, the structural relationships among the PCEs were confirmed by applying a Student’s t-test. Findings The classification of PCEs through driver dependence diagrams, structural digraphs of PCEs and statistical significance of the relationships between the PCEs are the main outcomes of this study. Further, certain PCEs (under supplier interest and common interest domains) were recommended in the Indian manufacturing environment to broadly control and monitor for achieving the preferred customer status (PCS). Research limitations/implications The current study provides certain basis for a manufacturer to selectively emphasize and monitor the right PCEs and in turn effectively achieve the PCS from its key suppliers. The findings from the current analysis are more applicable in the context of Indian automotive component manufacturing industry. Practical implications The outcomes from the methodology would provide a basis for a manufacturer to develop the right strategies to become a preferred supply chain partner. Originality/value Even though the concept of PCS or reverse marketing can make remarkable impact on the business practices, it has been an ignored topic of research and its practice has been passively prophesied. In this regard, the current study could be a worthy addition toward the practice of preferred customer concept.

An analysis of the status of resource flexibility and lean manufacturing in a textile machinery manufacturing company

2016 ◽  
Vol 24 (1) ◽  
pp. 107-122 ◽  
Author(s):  
Gulshan Chauhan
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Machine Flexibility ◽  
Content Type ◽  
Resource Flexibility ◽  
Manufacturing Company ◽  
The Status ◽  
Machinery Manufacturing ◽  
Labour Flexibility

Purpose – As the manufacturing industry is under pressure to face the global competition, it is necessary to improve productivity and reduce costs through minimization of wastage of resources for their survival. This paper aims to present an analysis of the status of resource flexibility and lean manufacturing through conducting a case study in an Indian textile machinery manufacturing company and also demonstrate the various areas of future scope for improving lean manufacturing. Design/methodology/approach – The case study has been conducted using the flexible system methodology (FSM) framework (Sushil, 1994). For measuring resource (labour and machine) flexibility and lean manufacturing, various factors contributing towards labour flexibility, machine flexibility and lean manufacturing are identified. To determine their relative weights, an analytical hierarchy process (AHP) has been used. A specially designed questionnaire is used to collect the information during case study on different aspects of resource flexibility and lean manufacturing. SAP-LAP analysis has also been carried out to look in to the ways the company is building up resource flexibility and lean manufacturing. Findings – The status of labour flexibility, machine flexibility and lean manufacturing is merely 49.30, 47.10 and 47.40 per cent, respectively. The most important factors of labour flexibility and machine flexibility attained a value of 59.50 and 61.17 per cent, respectively. Similarly, only 39.09 per cent wastes are eliminated through lean manufacturing. There is a huge scope to achieve a higher degree of lean manufacturing through focusing on continuous improvement, just in time (JIT) and resource flexibility factors. Research limitations/implications – The present study includes only labour and machines to compute the resource flexibility. Other resources may also be included to compute the overall resource flexibility. Practical implications – The present study provides guidelines to analyze the status of resource flexibility and lean manufacturing. According to conclusions, frail areas in the manufacturing system can be identified and a suitable course of action could be planned for the improvement. Hopefully, this study will help the firm’s management to identify the problems to manage resource flexibility and implement an effective lean manufacturing. Originality/value – In this work, the theoretical perspective has been used not only to update the original instrument, but also to study the subject from a perspective beyond that usually associated with resource flexibility and lean manufacturing.

Determinants of SME integration into global value chains

2017 ◽  
Vol 14 (3) ◽  
pp. 313-331 ◽  
Author(s):  
Chandra Mouli V.V. Kotturu ◽  
Biswajit Mahanty
Keyword(s):  
Manufacturing Industry ◽  
Global Value Chains ◽  
Value Chains ◽  
Production Networks ◽  
Global Production Networks ◽  
Key Factors ◽  
Automotive Component ◽  
Content Type ◽  
Factors Influencing ◽  
Component Manufacturing

Purpose In recent years, due to intense competition, small and medium-sized enterprises (SMEs) are unable to meet performance expectations and find difficulty in fulfilling the needs of the original equipment manufacturers (OEMs). Consequently, the growth of the SMEs has slowed down considerably. Constrained by their infrastructural resources, SMEs’ participation in global value chains (GVCs) has the potential to bring significant benefits, such as enhancing technological learning and innovation and generating positive contributions to the development of the SMEs. The purpose of this paper is to explore competitive priorities, key factors, and causal relationships influencing SMEs to enter GVCs. Design/methodology/approach In this paper, the GVC framework is adopted and qualitative feedback loop analysis is used to identify the key factors influencing the competitive factors. A questionnaire survey was carried out with the automotive component manufacturers of a transnational corporation in India. Findings The survey in the automotive component manufacturing industry reveals product quality standards as the most important priority for joining global production networks, followed by price competitiveness, timely delivery, innovativeness, manufacturing flexibility, service, and dependability. The qualitative findings reveal continuous personnel training, capacity expansion, research development, and others as key factors influencing competitiveness. Practical implications To retain SMEs’ role in economic development and to accelerate the growth of global production networks in India, thereby realizing opportunities from the emerging GVCs, support is needed for SMEs regarding the aspects identified in this study. Originality/value The study explores the dynamics of each competitive priority of SMEs in Indian automotive component manufacturing industry to enter the GVCs. No study has explored the dynamics of SMEs competitiveness to enter GVCs in the automotive manufacturing industry.

Assessment of CMMI level of manufacturing industry using fuzzy logic approach: a case study

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Tharun Thomas ◽  
Saleeshya P.G. ◽  
Suresh M.
Keyword(s):  
Fuzzy Logic ◽  
Manufacturing Industry ◽  
Manufacturing Sector ◽  
Triangular Fuzzy Number ◽  
Content Type ◽  
Study Approach ◽  
Capability Maturity ◽  
Fuzzy Logic Approach ◽  
Manufacturing Organization

Purpose The purpose of this study is to develop a CMMI model for the manufacturing industry and to find an appropriate method to assess the CMMI level. The CMMI level indicates how well the processes are planned, performed, measured and controlled, thus revealing the performance level of an organization. Design/methodology/approach Among the various process areas of CMMI, “organizational process focus” (OPF) is selected for the study. The CMMI model for the process area OPF is designed based on the CMMI enablers, criteria and attributes. Based on this multilevel model, a case study approach is adopted and fuzzy logic is used to measure the CMMI level of an organization. The fuzzy performance importance index (FPII) and the ranking score are used to further analyze the attributes. Findings The proposed model has been successfully used to measure the CMMI level of the manufacturing industry in south India. The triangular fuzzy number of the fuzzy CMMI measure index (FCMI) is obtained as (2.077, 3.534, 5.000). The transformation of FCMI back into linguistic terms discloses the current CMMI level of the industry as “Capability Maturity Level 2” (CML 2). Originality/value The authors tested the suitability of an inter-disciplinary approach known as CMMI for the process appraisal in the manufacturing sector. The investigation sets forth a unique framework to quantify the performance of practices followed in a manufacturing organization and thereby help the industry to realize the present strength and weakness in terms of process assets.

Lean machine manufacturing at Munjal Showa limited

2014 ◽  
Vol 63 (5) ◽  
pp. 644-664 ◽  
Author(s):  
Shivdasini Singh Amin ◽  
Rakesh Atre ◽  
Ankur Vardia ◽  
Boby Sebastian
Keyword(s):  
Cycle Time ◽  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Low Cost ◽  
Shop Floor ◽  
New Approach ◽  
Content Type ◽  
Indigenous Development ◽  
Depth Study ◽  
Increase Productivity

Purpose – The global manufacturing industry is becoming more competitive. Munjal Showa, a shock absorber manufacturer in India, is using indigenous development of lean machines by incorporating concepts of lean manufacturing and low-cost automation techniques to increase their competitiveness. This new approach has helped the company to reduce cost of manufacturing and to increase productivity by reducing cycle time and down time. The purpose of this paper is to offer an in depth study of how at Munjal Showa Ltd lean machines are being developed and manufactured. This paper explores how a cumbersome machine was transformed into a lean machine. Design/methodology/approach – This paper explores how a cumbersome machine was transformed into a lean machine. Findings – This new approach has helped the company to reduce cost of manufacturing and to increase productivity by reducing cycle time and down time. Research limitations/implications – The paper discusses the process of converting one cumbersome machine to a lean machine. Practical implications – Creativity before capital. In lean, team brainstorming of ideas and solutions is emphasized instead of spending large sums of money on capital expenditures Social implications – The cockpit model eases pressure of incumbents on the shop floor. Originality/value – The concepts espoused in the paper has increased productivity by 3.45 times and reduced costs.

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.

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