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.

Enigma of KAIZEN approach in manufacturing industry of Northern India – a case study

2018 ◽  
Vol 35 (1) ◽  
pp. 187-207 ◽  
Author(s):  
Jagdeep Singh ◽  
Harwinder Singh
Keyword(s):  
Manufacturing Industry ◽  
Manufacturing System ◽  
Management Approach ◽  
Successful Implementation ◽  
Practical Application ◽  
Content Type ◽  
Northern India ◽  
Manufacturing Environments ◽  
Effective Analysis

Purpose The purpose of this paper is to uncover the significance of KAIZEN technique in manufacturing environments. Design/methodology/approach KAIZEN is a management approach focused on incremental improvements in operations. Different elements of KAIZEN are being utilized by manufacturing industry to improve the performance of current manufacturing system processes. This study attempts to evaluate the performance of different elements of KAIZEN in manufacturing industry of Northern India. The importance level of different elements of KAIZEN, important benefits achieved after successful implementation of KAIZEN approach and benefits occurred after implementation of different elements of KAIZEN have been identified. Questionnaire survey in the case company has been performed and the most important element of KAIZEN has been implemented. Findings Results explicitly depict that failure mode and effective analysis is the most important element of KAIZEN. Results indicate the net savings of rupees 422,208 annually after implementing KAIZEN technique in a case company. Originality/value The paper demonstrates the practical application of KAIZEN technique showing how it can bring real breakthroughs in saving cost in the manufacturing industry.

SMED for quick changeover in manufacturing industry – a case study

2018 ◽  
Vol 25 (7) ◽  
pp. 2065-2088 ◽  
Author(s):  
Jagdeep Singh ◽  
Harwinder Singh ◽  
Inderdeep Singh
Keyword(s):  
Manufacturing Industry ◽  
Setup Time ◽  
Industrial Engineering ◽  
Small Scale ◽  
Small Enterprises ◽  
Production Environment ◽  
Content Type ◽  
Northern India ◽  
Manufacturing Environments

Purpose The purpose of this paper is to uncover the significance of SMED in manufacturing environments. Design/methodology/approach The paper gives setup instructions and guidelines to prepare the standardized setup procedure without ignoring actual constraints in production environment. It uses a case study in a small-scale manufacturing unit of northern India to generate an integrated setup reduction approach, utilizing Single Minute Exchange of Die (SMED)-based industrial engineering tools to achieve faster setups. It describes the feasibility of quick changeovers in small enterprises based on an “SMED” approach. Finally, the paper carries out empirical analysis of the financial/non-financial benefits incurred from setup reductions. Findings Setup activities are a vital part of the production lead time of any product and so affect overall product cost. Industrial engineering techniques have been used to analyze the existing procedure of setups. A SMED approach can help eliminate unwanted activities, externalize the internal activities, if possible, and reduce them by simplification or standardization. Originality/value The paper demonstrates the practical application of SMED showing how it can bring real breakthroughs in reducing setup time in small-scale manufacturing.

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.

A phase-wise approach to implement lean manufacturing

2019 ◽  
Vol 10 (1) ◽  
pp. 106-122 ◽  
Author(s):  
Gulshan Chauhan ◽  
Viral Chauhan
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Group Discussion ◽  
Manufacturing Companies ◽  
Productivity Improvement ◽  
Content Type ◽  
Flexible System ◽  
Cumulative Score ◽  
Mixed Approach ◽  
Practical Constraints

Purpose Today, manufacturing companies are facing a fierce competition and are under great pressure to cut costs for survival in the market. So emphasis is given to enhance quality, minimize waste, customer delight and increasing productivity through reduction in wastage of resources. But, most companies hesitate to implement all measures simultaneously to acquire lean manufacturing because of some practical/ capital constraints. Therefore, the purpose of this paper is to develop a phase-wise approach to implement lean manufacturing. Design/methodology/approach The paper opted for an exploratory study using the qualitative flexible system methodology framework proposed by Sushil (1994) and options field methodology proposed by Warfield (1982, 1990) including rigorous group discussion comprising the employees representing middle and senior management with productivity improvement backgrounds. The response of experts was recorded using a specially designed instrument in the light of the parameters suggested in group discussion. The measures/ actions were arranged in the decreasing order of their cumulative score. Findings The paper provides a phase-wise approach to implement lean manufacturing. Mixed approach is preferred over the other three approaches to implement lean manufacturing. Thirty measures/actions contributing to mixed approach are identified to implement lean manufacturing in three phases. A three-phase approach is developed: 10, 14 and six measures in the first, second and third phases, respectively, are identified to implement lean manufacturing after considering the practical constraints faced by the companies. Research limitations/implications All the measures/actions suggested to implement lean manufacturing are focused on the engineering manufacturing industry. Thus, the research results may lack generalizability and are limited to engineering manufacturing industry. The model developed in this research is based upon experts’ opinions. The experts’ opinion may be biased. The results of the model may vary in the real-world setting. Practical implications The present paper provides guidelines to practitioners for implementing lean manufacturing in phases. Hopefully, this study will motivate the firm’s management for implementing lean manufacturing and limiting the effect of practical constraints and scarcity of resources. Originality/value This paper fulfills and identifies the need to develop an approach to implement lean manufacturing phase wise because of practical constraints.

The challenges of lean manufacturing implementation in SMEs

2014 ◽  
Vol 21 (6) ◽  
pp. 987-1002 ◽  
Author(s):  
Anna Dorota Rymaszewska
Keyword(s):  
Lean Manufacturing ◽  
Small And Medium Enterprises ◽  
Successful Implementation ◽  
Case Study Method ◽  
Lean Implementation ◽  
Content Type ◽  
Implementation Challenges ◽  
Medium Enterprises ◽  
Manufacturing Environments

Purpose – The purpose of this paper is to identify the lean manufacturing implementation challenges in small and medium enterprises (SMEs). The study is based on experiences of the Finnish furniture and boating sectors. The paper outlines the overall characteristics of the studied organizations and contrasts them with one of the most famous example of lean implementation – the Toyota Company. By comparing the different manufacturing environments as well as organizational characteristics, the potential challenges of lean adoption are outlined. Design/methodology/approach – The findings presented in this paper were achieved through the case study method. The research utilizes the deductive approach. Findings – The results present an assessment of the companies’ current situations. The results uncover their readiness for lean implementation and identify the challenges that might hinder lean implementation. Early identification of weaknesses will make companies more aware of their own capabilities. Moreover, it has potential for making them better prepared for lean implementation and more consistent in their process. Practical implications – The importance of addressing certain aspect of lean implementation in the specific context of SMEs characteristics might contribute to the successful implementation of lean. Originality/value – The author presents an original look at supporting companies in the process of adopting lean manufacturing.

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.

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 investigation and prioritization of barriers toward implementation of agile manufacturing in the manufacturing industry

2020 ◽  
Vol 33 (1) ◽  
pp. 183-203
Author(s):  
Rahul Kumar ◽  
Kanwarpreet Singh ◽  
Sanjiv Kumar Jain
Keyword(s):  
Factor Analysis ◽  
Large Scale ◽  
Manufacturing Industry ◽  
Agile Manufacturing ◽  
Successful Implementation ◽  
Vikor Method ◽  
Content Type ◽  
Empirical Survey ◽  
Technological Constraints ◽  
Operational Constraints

PurposeThe study aims at empirically investigating and prioritizing the critical barriers for the successful implementation of agile manufacturing in the medium- and large-scale Indian manufacturing industries.Design/methodology/approachA literature review of peer-reviewed journals and discussion with experts is used to identify 17 barriers to the implementation of agile manufacturing. An empirical survey is then conducted to collect data regarding the agile manufacturing barriers and is further analyzed using the factor analysis and vlsekriterijumska optimizacija i kompromisno resenje (VIKOR).FindingsBased on the survey of empirical data, the investigated critical barriers were reduced in five critical categories, as follows: Managerial constraints, technological constraints, human resource–related constraints, operational constraints and organizational culture-related constraints, which are further ranked in terms of their severity using VIKOR. This research advocates the development of a strategy for addressing the most critical barriers instead of focusing on all for the successful implementation of agile manufacturing.Originality/valueThis work contributes to agile manufacturing literature by the structured presentation of the barriers to implement agile manufacturing in the Indian manufacturing industry. It also extends the integrated factor analysis and VIKOR method to investigate and rank the barriers.

Development of a structural model of environmentally conscious manufacturing drivers

2014 ◽  
Vol 25 (8) ◽  
pp. 1195-1208 ◽  
Author(s):  
Varinder Kumar Mittal ◽  
Kuldip Singh Sangwan
Keyword(s):  
Factor Analysis ◽  
Structural Equation ◽  
Manufacturing Industry ◽  
Structural Model ◽  
Equation Modeling ◽  
Special Focus ◽  
Successful Implementation ◽  
Environmentally Conscious ◽  
Content Type ◽  
Environmentally Conscious Manufacturing

Purpose – Manufacturing firms consume energy and natural resources in highly unsustainable manner and release huge amounts of green house gases leading to many economic, environmental and social problems; from local waste disposal to climate change. Consciousness about these issues has lead to a new manufacturing paradigm of environmentally conscious manufacturing (ECM). There exist many social, legislative, policy, economic, internal, and environmental factors which can motivate and/or force industry to adopt ECM. The purpose of this paper is to identify the drivers for ECM, developing a model of these drivers using statistical analysis and testing the model using structural equation modeling (SEM) technique. Design/methodology/approach – The basic steps of methodology are ECM driver development, survey instrument development, data collection, model proposition, and model validation. The main data analysis approaches are exploratory factor analysis, confirmatory factor analysis, and SEM to develop a model of drivers and validating the same based on the data collected from the manufacturing industry. Findings – The reliable, valid, and tested model has three types of drivers – internal, policy, and economic. It has been found through hypothesis testing that internal drivers for the implementation of ECM are positively related to policy and economic drivers; and policy drivers are positively related to economy drivers. This research is expected to help government and industry in developing policies and strategies for the successful implementation of ECM. Practical implications – The novelty of this study is that it provides the relationship among the drivers which can be leveraged by the managers to focus on the root drivers for smooth and effective implementation of ECM. Originality/value – This paper provides new theoretical insight into the factors motivating the industry to implement ECM systems in the industry with special focus on manufacturing sector of emerging economies.

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