Validity and reliability of lean manufacturing frameworks

2014 ◽  
Vol 5 (4) ◽  
pp. 361-391 ◽  
Author(s):  
Naga Vamsi Krishna Jasti ◽  
Rambabu Kodali
Keyword(s):  
Frequency Analysis ◽  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Research Work ◽  
Middle Level ◽  
Manufacturing Industries ◽  
Validity And Reliability ◽  
Content Type ◽  
Survey Tool ◽  
Industry Sector

Purpose – The purpose of this paper is to investigate, validity and reliability analysis on existing Lean manufacturing (LM) frameworks when applied to Indian organizations. LM is one of the best manufacturing strategies that are used by manufacturing plant managers to improve manufacturing capabilities. Design/methodology/approach – In the present research work, a questionnaire-based survey was used to examine 35 LM frameworks. The study targeted respondents ranging from top- and middle-level management personnel in Indian manufacturing industry. The sample includes organizations in a variety of industries ranging from automobile, electronics, engineering, process and textile industries products. The survey tool was prepared with team of 12 members i.e. six academicians and six professionals from manufacturing industry environment. The study received 186 responses from various sectors of manufacturing industry, 180 surveys were usable resulting in a response rate of 23.90 per cent. Factor analysis was conducted to check unidimentionality of the framework. Cronbach’s alpha is calculated to find reliability of each framework’s. Lastly, frequency analysis was used to recognize familiar constructs of LM on the chosen framework. Findings – This study has identified that most of the LM frameworks revealed a high level of reliability. When the study has examined further advance about unidimensionality with respect to the construct, i.e. the LM it measures, it confirmed 11 frameworks were revealing unidimensionality. The frequency analysis was evident that a greater part of the constructs has a high mean score and mode. Finally, the research concludes that there is requirement for a novel framework to Indian manufacturing industry to stay in competition with global manufacturing industries. Research limitations/implications – Cross-sectional data from manufacturing industries and India (only one country) is used with sample size restricted to 180 only, and it would be interesting to test these frameworks for more than one industry sector and country. Practical implications – The present work tries to find the suitability of the presented LM frameworks to Indian manufacturing industry sector. The authors hoped that the present research would give the information to the management to execute the suitable LM framework in their firm. Originality/value – The present work tries to find the suitability of the presented LM frameworks to Indian manufacturing industry sector. The authors hoped that the present research would give the information to the management to execute the suitable LM framework in their firm.

Strategic impact of SCM and SCQM practices on competitive dimensions of Indian manufacturing industries

2019 ◽  
Vol 31 (5) ◽  
pp. 696-721 ◽  
Author(s):  
Mandeep Kaur Sidhu ◽  
Kanwarpreet Singh ◽  
Doordarshi Singh
Keyword(s):  
Business Performance ◽  
Large Scale ◽  
Manufacturing Industry ◽  
Discriminant Validity ◽  
Research Work ◽  
Manufacturing Industries ◽  
Combined Approach ◽  
Total Quality ◽  
Content Type ◽  
Manufacturing Organizations

Purpose The purpose of this paper is to evaluate the capabilities of total quality management (TQM) and supply chain management (SCM) and extract various significant factors which influence the implementation of SCM alone and synergy of both TQM–SCM in terms of business performance of Indian medium and large scale manufacturing industry. Design/methodology/approach In the present study, 116 Indian manufacturing organizations have been extensively surveyed to ascertain the inter-relationships between various success factors and competitive dimensions of SCM alone and for combined approach (TQM–SCM), through different statistical techniques. Further, to evaluate the significance of time period on competitive dimensions, two-tailed t-test has been deployed. Finally the discriminant validity test has been applied to extract highly successful and moderately successful organizations for both approaches. Findings The study compares the contributions played by only SCM initiatives and combined approach (TQM–SCM) initiatives toward realization of significant improvements of various competitive dimensions of Indian manufacturing organizations. Finally, this study reveals that synergistic relationship of TQM and SCM paradigms can be more helpful as compared to only SCM initiatives for Indian manufacturing industries to enhance overall business performance. Originality/value TQM and SCM are considered as performance improvement techniques by the manufacturing organizations. The present research work establishes that combined (TQM–SCM) initiatives have effectively contributed for realization of significant competitive dimensions, progressively from introduction to maturity phases. So, the study stresses upon the need for improving coordination between various manufacturing parameters as well as competitive dimensions of TQM and SCM paradigms to enjoy higher potential of business performance.

A systematic literature review of lean manufacturing implementation in manufacturing-based sectors of the developing and developed countries

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Catherine Maware ◽  
Modestus Okechukwu Okwu ◽  
Olufemi Adetunji
Keyword(s):  
Developing Countries ◽  
Literature Review ◽  
Lean Manufacturing ◽  
Negative Impact ◽  
Developed Countries ◽  
Manufacturing Industries ◽  
Preliminary Review ◽  
Content Type ◽  
Manufacturing Organizations ◽  
Developing And Developed Countries

Purpose This study aims to comparatively discuss the effect of lean manufacturing (LM) implementation in the manufacturing sectors of developing and developed countries. Design/methodology/approach An in-depth literature review focused on previous research published between 2015 and March 2020. The papers published by the databases such as Google Scholar, Scopus, ProQuest and Web of Science were used in the study. A total of 63 studies that focused on LM application in manufacturing industries in developing and developed countries were used in the research. Findings It was observed that LM improves operational performance for manufacturing organizations in developing and developed countries. Small and medium-sized enterprises in both developed and developing countries have difficulties transforming their organizations into lean organizations compared to large enterprises. Furthermore, the review also found that there seems to have been no paper had reported the negative impact of implementing LM in manufacturing industries in developing and developed countries from 2015 to March 2020. Research limitations/implications The study used research papers written between January 2015 and March 2020 and only considered manufacturing organizations from developed and developing nations. Practical implications The study provides more insight into LM implementation in developing and developed countries. It gives the LM practices and the implications of applying these practices in manufacturing organizations for developing and developed countries. Originality/value A preliminary review of papers indicated that this seems to be the first paper that comparatively studies how LM implementation has affected manufacturing organizations in developed and developing countries. The study also assessed the LM practices commonly used by the manufacturing industries in developing and developed countries.

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.

Qualitative study of challenges and strategies of Indian IT organizations toward global branding

2019 ◽  
Vol 27 (2) ◽  
pp. 708-731 ◽  
Author(s):  
Keshab Ray ◽  
Meenakshi Sharma
Keyword(s):  
Qualitative Study ◽  
Competitive Advantage ◽  
Research Work ◽  
Middle Level ◽  
Human Potential ◽  
Brand Strength ◽  
Content Type ◽  
Global Branding ◽  
It Organizations ◽  
The Impact

Purpose There is a lacuna in research work in terms of understanding how Indian IT organizations can become global brands. Benchmarking has not received much attention in marketing literature due to lack of benchmarking framework, and IT organizations are yet to make progress in benchmarking. The purpose of this paper is to examine the impact of brand strength on global branding by developing a conceptual benchmarking framework for Indian IT organizations. Design/methodology/approach Semi-structured in-depth interviews are conducted with thirty middle-level managers from two Indian IT organizations, two US-based global IT organizations and one UK-based leading bank, which is a customer of these IT organizations. Findings Results show a positive relationship between brand strength and global branding, between customer loyalty and global branding, between brand loyalty and competitive advantage and between global branding and competitive advantage. Indian IT organizations can benchmark global IT organizations to improve delivering brand promise, positioning, awareness building and authenticity toward making Indian IT organizations future ready to address the entire breadth of opportunities in the evolving world of cloud and digital. Practical implications This research helps managers with a brand strength-based benchmarking framework toward global branding of Indian IT organizations. Social implications IT is instrumental for rapid growth of Indian’s economy. India should optimally utilize its greatest wealth, its human potential, with the latent global demand in IT through building global IT brands. Originality/value The originality of the study lies in conducting a qualitative study on global branding of Indian IT organizations and also proposing a conceptual benchmarking framework. The study further validates the model using qualitative analysis.

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.

Productivity improvement using lean manufacturing in manufacturing industry of Northern India

2018 ◽  
Vol 67 (8) ◽  
pp. 1394-1415 ◽  
Author(s):  
Jagdeep Singh ◽  
Harwinder Singh ◽  
Gurpreet Singh
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Management Approach ◽  
Successful Implementation ◽  
Productivity Improvement ◽  
Content Type ◽  
Manufacturing Technique ◽  
Northern India ◽  
Lean Tools ◽  
Manufacturing Environments

Purpose The purpose of this paper is to uncover the significance of lean manufacturing technique in manufacturing environments. Design/methodology/approach Lean manufacturing is a management approach focused on incremental improvements in operations. Different lean strategies are being utilized by manufacturing industry to improve the performance of current manufacturing system processes. This study attempts to evaluate the performance of different lean manufacturing tools in the manufacturing industry of northern India. The importance level of different lean tools, important benefits achieved after successful implementation of lean manufacturing approach and benefits occurred after implementation of different lean tools have been identified. A questionnaire survey in the case company has been performed and the most important element of lean manufacturing has been implemented. Findings Results explicitly depict that just-in-time manufacturing is the most important element of lean manufacturing. Results indicate the net savings of rupees 242,208 annually after implementing lean manufacturing technique in a case company. Originality/value The paper demonstrates the practical application of lean technique showing how it can bring real breakthroughs in saving cost in the manufacturing industry.

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.

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.

scholarly journals Implementation of lean tools and techniques in an ethical papers production industry

2021 ◽  
Vol 5 (2) ◽  
pp. 63-73
Author(s):  
Kukhan S ◽  
Bhuvanesh Kumar M
Keyword(s):  
Lean Manufacturing ◽  
Best Practice ◽  
Continuous Production ◽  
Paper Industry ◽  
Continuous Process ◽  
Research Work ◽  
Manufacturing Industries ◽  
Raw Material ◽  
Lean Tools ◽  
Production Industry

Lean manufacturing (LM) is established as a best practice to improve the performance of manufacturing industries. Not all the manufacturing industries realize the benefits of LM practices specifically continuous process industries. The present research work is intended to study the advantages of implementing LM practices in an ethical paper industry which is a continuous production industry. Presently, the industry suffers with the problems such as lack of productivity, raw material wastes, underutilized resources, and lack of standard practices in the production. Gemba technique is adapted to record the information related to the present manufacturing environment. Based on the current state analysis, the feasible lean tools are selected and implemented such as 5S, Kaizen, and Total Productive Maintenance (TPM). The improvements have been noted as reduced tool change over time, reduced material wastes, effective utilization of resources and provide safety guidelines to workers and operations. The implications of these improvements increased the productivity also.

A relational analysis of drivers and barriers of lean manufacturing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Bharat Singh Patel ◽  
Murali Sambasivan ◽  
R. Panimalar ◽  
R. Hari Krishna
Keyword(s):  
Lean Manufacturing ◽  
Structural Model ◽  
Middle Level ◽  
Lean Management ◽  
Content Type ◽  
Structural Hierarchy ◽  
Bottom Level ◽  
Lean Practices ◽  
Novel Approach ◽  
The Impact

PurposeThe 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/approachA 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.FindingsBased 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 implicationsThe 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/valueThis 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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