Prioritization and ranking of lean practices: a case study

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Narpat Ram Sangwa ◽  
Kuldip Singh Sangwan
Keyword(s):  
Value Chain ◽  
Hierarchical Models ◽  
Structural Model ◽  
Structural Models ◽  
Automotive Component ◽  
Content Type ◽  
Lean Practices ◽  
Performance Dimensions ◽  
Component Manufacturing ◽  
Manufacturing Organization

PurposeThe paper aims to identify, prioritize and rank lean practices in the context of an Indian automotive component manufacturing organization using interpretive ranking process (IRP) and interpretive structural modeling (ISM) approaches.Design/methodology/approachLean practices are identified from the literature. Then, two hierarchical models were are developed using two distinct modeling approaches – ISM and IRP with expert opinions from an Indian automotive component manufacturing organization to analyze the contextual relationships among the various lean practices and to prioritize and rank them with respect to performance dimensions.FindingsIn the study, the hierarchical structural models are developed using ISM and IRP approaches for an Indian automotive component manufacturing organization. In ISM-based modeling, lean practices can be categorized into five levels. Top priority should be given to the motivators followed by value chain, system/technology and organization centric practices. IRP model shows the dominance relationship among the various lean practices with respect to performance dimensions.Practical implicationsThe models are constructed from the organizational standpoint to evaluate their impact to the implementation of lean manufacturing. The study leverages the organizations to prioritize limited resources as per the hierarchy. Managers get the inter-linkages and ranking of various lean practices, which leads to a better perspective for the effective implementation of lean. The structural models also assist management to assign proper roles to employees/departments for effective lean implementation.Originality/valueThere is hardly any structural model of lean practices in the literature for clustering, prioritizing and ranking of lean practices. The study fills this gap and develops the hierarchical models of lean practices through IRP and ISM approaches for an Indian automotive component manufacturing organization. The results from both approaches are compared for illustrating the benefits of one over the other.

Deploying Lean Six Sigma framework in an automotive component manufacturing organization

2016 ◽  
Vol 7 (3) ◽  
pp. 267-293 ◽  
Author(s):  
Vikas Swarnakar ◽  
S. Vinodh
Keyword(s):  
Six Sigma ◽  
Assembly Line ◽  
Lean Six Sigma ◽  
Bottom Line ◽  
Defect Reduction ◽  
Automotive Component ◽  
Content Type ◽  
Component Manufacturing ◽  
Manufacturing Organization ◽  
Tools And Techniques

Purpose This paper aims to deploy Lean Six Sigma (LSS) framework to facilitate defect reduction and enhance bottom line results of an automotive component manufacturing organization. Design/methodology/approach LSS is a business process improvement strategy widely used in the manufacturing field for enhancing manufacturing organization performance. The integration of Lean and Six Sigma will enable the attainment of defects reduction by eliminating non-value-adding activities from production line. LSS framework has been developed with the integration of define–measure–analysis–improve–control (DMAIC) tools and techniques. Findings The finding of this study is that the LSS framework has been successfully implemented in automotive component manufacturing organization, and non-value-adding activities and defects from assembly line have been reduced. The proposed LSS framework applies lean tools within Six Sigma DMAIC approach to facilitate waste elimination and defect reduction. The developed framework with linkage of DMAIC tools and techniques reduces defects and non-value-adding activities with enhanced bottom line results. The implementation of proposed LSS framework shows effective improvement in key metrics. Research limitations/implications The developed framework has been test implemented in an automotive component manufacturing organization. In future, more number of studies could be conducted. Further, advanced lean tools and techniques could be included in the framework for increasing the effectiveness of production line. Practical implications The proposed LSS framework with linkage of DMAIC tools and techniques has been successfully implemented in an assembly line of automotive component manufacturing organization. This method is presently applied for an automotive component manufacturing organization; in future, the approach could be applied in different industrial sectors with addition of new tools and techniques for improving its effectiveness. Originality/value LSS framework has been designed and test implemented in an assembly line of an automotive component manufacturing organization. Hence, the inferences are practical and key results of the study.

Lean Six Sigma project selection using hybrid approach based on fuzzy DEMATEL–ANP–TOPSIS

2015 ◽  
Vol 6 (4) ◽  
pp. 313-338 ◽  
Author(s):  
S Vinodh ◽  
Vikas Swarnakar
Keyword(s):  
Decision Making ◽  
Six Sigma ◽  
Hybrid Approach ◽  
Project Selection ◽  
Lean Six Sigma ◽  
Automotive Component ◽  
Content Type ◽  
Industrial Sectors ◽  
Component Manufacturing ◽  
Manufacturing Organization

Purpose – The purpose of this paper is to select the optimal Lean Six Sigma (LSS) project using hybrid fuzzy-based Multi-Criteria Decision-Making (MCDM) approach for an automotive component manufacturing organization. Design/methodology/approach – The LSS project selection has been formulated as the MCDM problem. Hybrid MCDM method based on Decision-Making Trial and Evaluation Laboratory Model (DEMATEL), Analytical Network Process (ANP) and Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) has been used to select the optimal LSS project. The methodology enabled the practitioners to systematically prioritize LSS projects. Findings – The finding of this study is that, out of five LSS projects, project P3 is the best LSS project. P3 is the optimal LSS project with reduced failure risk, and efforts are being taken to implement the selected project. Research limitations/implications – The problem formulation and methodology has been tested for a single study. In future, more number of studies could be conducted using the hybrid approach. This method is presently applied for an automotive component manufacturing organization; in future, the approach could be applied in different industrial sectors for improving its effectiveness. Practical implications – The case study has been conducted in a real-time industrial problem. The practitioners expressed the usefulness of the methodology for prioritizing LSS projects Hence, the inferences derived are found to possess practical relevance. Originality/value – The original contribution of the study is the selection of optimal LSS project using hybrid MCDM technique.

Sustainable logistics barriers of fruits and vegetables

2018 ◽  
Vol 25 (8) ◽  
pp. 2589-2610 ◽  
Author(s):  
Rakesh Raut ◽  
Bhaskar B. Gardas
Keyword(s):  
Supply Chain ◽  
Value Chain ◽  
Fruits And Vegetables ◽  
Structural Model ◽  
Fresh Produce ◽  
Sustainable Transportation ◽  
Three Dimensions ◽  
Interpretive Structural Modeling ◽  
Content Type ◽  
Sustainable Logistics

PurposeThe reduction of food wastage at every stage of a fresh produce supply chain helps in achieving balance among all three dimensions (social, ecological and economic) of the sustainability and helps in stimulating the growth and development in the agricultural domain. The purpose of this paper is to address the causal factors of post-harvesting losses (PHLs) occurring in the transportation phase.Design/methodology/approachThrough exhaustive literature survey and expert opinions, 12 crucial barriers to sustainable transportation of fruits and vegetables (F&V) are identified. The interpretive structural modeling (ISM) methodology, a multi-criteria decision-making (MCDM) approach, is employed for developing a structural model of the identified barriers.FindingsThe results of the analysis highlighted that two factors, namely, the non-availability of refrigerated vehicles, and excessive loading on the vehicles, are the most significant barriers to sustainable transportation which are found to have the highest driving power.Research limitations/implicationsThe results of the present research are applicable to the F&V supply chains only. The established interrelation among the identified factors depends on the judgments given by the experts which could be biased. The developed ISM model is intended to guide the policy and decision makers for formulating the policies for the performance improvement of the fresh produce value chain.Originality/valueIt is the first research of its kind focusing on the model development of critical factors causing PHLs in the transportation phase of the agricultural fresh produce supply chain using MCDM process.

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.

Agility and lean practices as antecedents of supply chain social sustainability

2020 ◽  
Vol 40 (10) ◽  
pp. 1589-1611 ◽  
Author(s):  
Vishnu Nath ◽  
Rajat Agrawal
Keyword(s):  
Supply Chain ◽  
Management Practices ◽  
Structural Model ◽  
Social Sustainability ◽  
Operational Performance ◽  
Validity And Reliability ◽  
Content Type ◽  
Sustainability Performance ◽  
Lean Practices ◽  
Sustainability Practices

PurposeThe present study aims to empirically investigate whether supply chain agility and lean management practices are antecedents of supply chain social sustainability.Design/methodology/approachData were collected from 311 supply chain practitioners from the Indian manufacturing sector. Confirmatory factor analysis was employed to test the validity and reliability of the measures used, and a structural model was analyzed to test the hypotheses of the current study.FindingsThe results indicate that agility and lean practices are significant antecedents of social sustainability orientation as well as social sustainability performance. The results also suggest that agility has a significant indirect effect on operational performance via social sustainability orientation, basic social sustainability practices as well as agility is indirectly affecting social sustainability performance via social sustainability orientation and basic social sustainability practices.Practical implicationsThe results of the present study have implications for managers that want to make their supply chain more socially sustainable.Originality/valueThe study is unique in the sense that it empirically links agility and lean practices with social sustainability orientation, social substantiality performance and operational performance in supply chains.

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.

Performance obstacles in sustainable manufacturing – model building and validation

2020 ◽  
Vol 17 (4) ◽  
pp. 549-566
Author(s):  
Priyanka Pathak ◽  
M.P. Singh ◽  
Gaurav Kumar Badhotiya
Keyword(s):  
Factor Analysis ◽  
Literature Review ◽  
Structural Equation ◽  
Structural Model ◽  
Sustainable Manufacturing ◽  
Equation Modeling ◽  
Content Type ◽  
Manufacturing Organization ◽  
Critical Literature ◽  
Performance Obstacles

PurposeManufacturing organization has adopted the concept of sustainability to improve the performance of product and process as well as to focus on environmental issues. Despite technological advancements and awareness, there exist several performance obstacles for the implementation of sustainable manufacturing in an organization. The objective of the current study is to identify the performance obstacles, propose a structural model and validate the proposed model.Design/methodology/approachTwelve performance obstacles are identified through critical literature review and discussion with field experts. Primary and secondary factor analysis, that is, exploratory factor analysis (EFA) and confirmatory factor analysis (CFA), are used for the creation of the structural model, and further, structural equation modeling is used as a validating tool. EFA deals with the categorization of all performance obstacles in four major criteria, and CFA works for proposing a model for a relationship among all obstacles.FindingsA validated structural model is provided through hypothesis acceptance for structural equation modeling. The outcome of this study can be helpful for decision-makers to incorporate sustainable practices in the manufacturing organization.Originality/valueThis study has extracted and identified performance obstacles for the implementation of sustainable manufacturing based on critical literature review and discussion with field experts. The study proposes as well as validates the structural equation model.

TISM for analysis of barriers affecting the adoption of lean concepts to electronics component manufacture

2020 ◽  
Vol 11 (6) ◽  
pp. 1141-1173
Author(s):  
Senthil Kumar D. ◽  
S. Vinodh
Keyword(s):  
Structural Model ◽  
Matrix Multiplication ◽  
Change Agents ◽  
Practical Case ◽  
Interpretive Structural Modeling ◽  
Content Type ◽  
Management Commitment ◽  
Top Management Commitment ◽  
Component Manufacturing ◽  
Selection Of

Purpose The purpose of this paper is to present the analysis of barriers affecting the adoption of lean concepts to electrical and electronics component manufacturing. Design/methodology/approach Lean concepts are being increasingly applied by electrical and electronics component manufacturers to enhance product value through streamlined process. To facilitate smooth adoption of lean concepts, barriers need to be analyzed and prioritized. In this context, a structural model of 24 barriers is developed through total interpretive structural modeling (TISM) approach. Findings ‘Changing governmental policies,’ ‘poor selection of change agents and improvement teams,’ ‘lack of top management commitment understanding and support of the system,’ ‘lack of team autonomy,’ ‘lack of flexibility and versatility’ and ‘lack of customer focus/involvement’ are found to be the dominant barriers based on TISM study. Interpretation statements are being derived from TISM model. Cross-impact matrix multiplication applied to classification analysis is conducted. Research limitations/implications In the present paper, 24 barriers are considered. In future, additional barriers could be considered to deal with managerial advancements. Practical implications The paper reports the practical case of analysis of barriers to lean adoption in electronics component manufacture. Hence, the inferences have practical relevance. Originality/value The development of structural model for the analysis of barriers to lean implementation in electronics component manufacturing small- and medium-sized enterprises is the original contribution of the authors.

scholarly journals Influence of lean–green practices on organizational sustainable performance

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Manori Pathmalatha Kovilage
Keyword(s):  
Performance Measures ◽  
Management Practices ◽  
Structural Model ◽  
Inventory Level ◽  
Green Management ◽  
Content Type ◽  
Sustainable Performance ◽  
Lean Practices ◽  
Green Practices ◽  
Lean And Green

PurposeThe key objectives of this study were to investigate the interactions among the lean, green management practices and organizational sustainable performance measures and explore the possibility of simultaneous implementation of these concepts for improving the organizational sustainable performance.Design/methodology/approachUsing the interpretive structural modeling (ISM) technique, the interactions among the lean, green practices and organizational sustainable performance measures were established. A focus group which consisted of purposively selected 15 experts was utilized in the primary data collection.FindingsIn Sri Lankan context, water and material consumption reduction, energy efficiency, water pollution and greenhouse gas reduction were identified as the dominant green practices, while pull production, lot size reduction, continuous improvement, preventive maintenance, employee involvement and cycle time reduction were the dominant lean practices. Inventory level, profitability, quality, cost, employee satisfaction, customer satisfaction, lead time, resources consumption (material, water, energy) and waste generation were determined as the dominant sustainable performance measures. The resulting ISM-based structural model which consisted of eight levels concluded that firstly lean practices influence the green practices and afterward green practices affect the sustainable performance measures.Research limitations/implicationsThe aim of this study was to develop a hypothetical structural model to explain the interactions among the lean, green management practices and organizational sustainable performance measures. But this hypothetical model was not empirically tested in the current study. So further study is required to empirically test the proposed model.Practical implicationsCurrently organizations who practice for sustainable performance engages, lean and green practices separately without understanding on which practices are stared when and how. So, through the findings of this study, organization who desire to improve the sustainable performance are recommended to begin the journey with lean practices and subsequently move in to green and handle both lean and green initiatives through one functional unit.Originality/valueThe existing literature does not possess a model for explaining the lean–green synergy and organizational sustainable performance and this study successfully fills this gap. Also the study proposes for the practitioners, when and how the lean and green practices should be initiated and implemented for rising the sustainable performance of an organization.

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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