Variable pay and job performance of shop-floor workers in lean production

2016 ◽  
Vol 27 (2) ◽  
pp. 287-311 ◽  
Author(s):  
Vathsala Wickramasinghe ◽  
G.L.D. Wickramasinghe
Keyword(s):  
Job Performance ◽  
Structural Equation ◽  
Production Systems ◽  
Lean Production ◽  
Manufacturing Firms ◽  
Shop Floor ◽  
Design Features ◽  
Content Type ◽  
Variable Pay ◽  
Lean Production Systems

Purpose – The purpose of this paper is to investigate design features of variable pay plans adopted for shop-floor workers engaged in manufacturing firms that had implemented lean production systems, and the effects of design features on their job performance. Design/methodology/approach – In total, 892 shop-floor workers attached to lean implemented manufacturing firms in Sri Lanka responded for the study. Structural equation modelling was used for the data analysis. Findings – It was found that the performance evaluation-base for variable payments, variable pay calculation-base and goal setting for variable pay significantly predict job performance of the shop-floor workers. Originality/value – It could be expected that the academics and practitioners alike are motivated by their desire to clearly apprehend the contribution of variable pay plans on job performance of the shop-floor workers engaged in lean production systems. This demands more investigations to better understand the design features of variable pay plans.

Effects of continuous improvement on shop-floor employees’ job performance in Lean production

2016 ◽  
Vol 20 (4) ◽  
pp. 182-194 ◽  
Author(s):  
G.L.D. Wickramasinghe ◽  
Vathsala Wickramasinghe
Keyword(s):  
Job Performance ◽  
Continuous Improvement ◽  
Design Methodology ◽  
Production Systems ◽  
Lean Production ◽  
Shop Floor ◽  
Full Time ◽  
Content Type ◽  
Textile And Apparel ◽  
Lean Production Systems

Purpose The purpose of this paper is to present empirical findings of the effect of continuous improvement (CI) on shop-floor employees’ job performance in the Lean production system-implemented textile and apparel firms. Design/methodology/approach A random sample of 657 shop-floor employees engaged full-time in Lean production systems-implemented textile and apparel firms in Sri Lanka responded to the survey. Statistical methods were used for data analysis. Findings It was revealed that CI significantly and positively influences shop-floor employees’ job performance, and the duration of Lean production in operations (termed as Lean duration) moderates this relationship. Originality/value Investigations on the ways in which CI initiatives influence employees is important in creating an environment to sustain the improvement efforts over a longer period. Such lessons would be valuable for academics and practitioners alike worldwide.

A FMEA-based approach to prioritize waste reduction in lean implementation

2014 ◽  
Vol 31 (4) ◽  
pp. 346-366 ◽  
Author(s):  
Ruy Victor B. de Souza ◽  
Luiz Cesar R. Carpinetti
Keyword(s):  
Production Systems ◽  
Lean Production ◽  
Waste Reduction ◽  
Effect Analysis ◽  
Content Type ◽  
Order Processing ◽  
Common Causes ◽  
Flow Of Information ◽  
Lean Production Systems

Purpose – This paper presents a proposal of adaptation of the failure mode and effect analysis method to analyze wastes and define priorities for actions aimed at minimizing or eliminating these wastes based on the criteria of severity, occurrence and detection. Design/methodology/approach – The proposition was developed in parallel to the implementation of a lean production system of a manufacturing company. A pilot application of the proposal was based on the analysis of a flow of information for order processing. Findings – Application of the proposed procedure results in a classification of levels of priority for waste reduction of the analyzed waste modes. Following this procedure, high priority will be given to actions focused on the elimination or minimization of the most common causes of the most severe waste modes. Originality/value – Prioritization of actions to minimize waste is essential to sustain lean production systems. However, identifying the wastes most in need of attention is not always straightforward and methods presented in the literature to evaluate leanness do not focus on waste reduction prioritization. Adoption of the proposed technique can certainly aid planning implementation and improvement of lean production programs, and in the end, it can contribute to the effectiveness and sustainability of lean production systems.

Procedure model to integrate digital elements into lean production systems

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Christoffer Rybski ◽  
Roland Jochem
Keyword(s):  
Industry 4.0 ◽  
Process Model ◽  
Production Systems ◽  
Lean Production ◽  
Current Status ◽  
German Industry ◽  
Extensive Literature ◽  
Literature Analysis ◽  
Content Type ◽  
Lean Production Systems

Purpose Industry 4.0 is one of the most used terms in the current industrial discussion. There are several perspectives and approaches related to Industry 4.0 so far, but no universal definition. Often-mentioned basic requirements to “implement” Industry 4.0 are lean and well-organized processes. In the past and still until today, a lot of companies try to implement lean production systems (LPS) according to the example of Toyota to realize a systematic approach to ensure well-organized processes. The process model aims to support organizations to integrate Industry 4.0 elements into LPS, regardless of the size of the organization. The purpose of this paper to describe a model as a first basis for further elaborations that could focus on the detailed design of each model-phases. Furthermore, the identified digital elements of Industry 4.0 build a first foundation to choose pilot projects related to existing challenges of the organizations LPS. In this context, especially the suitability of LPS and Industry 4.0 elements should be further investigated. Design/methodology/approach To investigate the current status regarding the realization of Industry 4.0 approaches and related challenges in the German industry, the two authors realized a survey with over 300 participants from different sectors and company sizes, using an online questionnaire. The results of the survey will be a part of this paper and a technology analysis, which was the outcome of an extensive literature analysis. The results were summarized in a model to integrate digital elements into existing LPS. Practitioners can use the process model as a first orientation to integrate industry 4.0 technologies into their existing LPS, based on specific challenges with their LPS processes. Findings Even if most of the participating German companies recognize Industry 4.0 as an important or very important topic, many of them do not consider themselves well prepared. The participants see huge challenges with regard to the needed qualifications and investments Industry 4.0 requires. In general, the companies hope to improve productivity and customer satisfaction to name two main objectives of the implementation of digital elements of Industry 4.0. In addition to the survey, a profound literature analysis was made and identified eight core digital elements. On this basis a milestone-based model to integrate these digital elements into existing LPS was developed. Originality/value This paper considers results from a study and analysis regarding the potentials of digital elements of Industry 4.0 for production system from different angles and introduces a model for integrating these elements.

Developing a robust measurement instrument for the influence of national culture on lean production systems

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Enrique Macias de Anda ◽  
Rupy Sawhney ◽  
Guilherme Luz Tortorella
Keyword(s):  
National Culture ◽  
Structural Equation ◽  
Production Systems ◽  
Lean Production ◽  
Group Analysis ◽  
Measurement Instrument ◽  
Production Model ◽  
Equation Modeling ◽  
Content Type ◽  
Novel Approach

Purpose The purpose of this study is to provide a robust model to bridge the influence of national culture (NC) on lean production (LP), identifying relationships among their elements and investigating the degree of influence. Design/methodology/approach The culturally sensitive lean production model (CSLPM) is used as a framework to develop a survey questionnaire that captures the information to analyze using partial least squares structural equation modeling (PLS-SEM). A case study to validate the model is presented from a subsidiary with operations in Mexico (MX) and the USA. Findings The CSLPM provides a robust framework for the measurement of the interaction between LP and NC. Multi-group analysis facilitated the comparison among the different groups (MX and USA), highlighting the differences of culture and the corresponding LP implementation within the same company. Research limitations/implications The instrument was validated only within two countries and one organization. A higher sample of respondents, countries and organizations could validate the relationships established and the replication of the model. Practical implications The CSLPM can be used for assessment of the evolution of organizations, highlighting strengths and weaknesses of a particular culture when implementing LP, providing focal points for research and training efforts. Originality/value The CSLPM is a robust instrument to measure expectations for LP practices according to their company’s geographical context. The incorporation of higher order variables and mixed directionality within the variables presented a novel approach to PLS-SEM.

Rolling out lean production systems: a knowledge-based perspective

2016 ◽  
Vol 36 (1) ◽  
pp. 61-85 ◽  
Author(s):  
Raffaele Secchi ◽  
Arnaldo Camuffo
Keyword(s):  
Design Research ◽  
Production Systems ◽  
Lean Production ◽  
Theory And Practice ◽  
Structured Interviews ◽  
Data Set ◽  
Content Type ◽  
Knowledge Based ◽  
Roll Out ◽  
Lean Production Systems

Purpose – Adopting a knowledge-based perspective, the purpose of this paper is to investigate the roll-out process of lean production systems and explores the dimensions that might enhance or hinder its performance. It develops a framework to understand and design lean roll-out processes, identifying the research dimensions/design variables to classify and interpret such processes. Design/methodology/approach – This exploratory multiple case study analyses seven lean roll-out processes in multinational companies’ plants. An original data set, developed on the basis of a purposely design research protocol, was built through two rounds of plant visits and structured interviews. The cross-case analysis compares and contrasts the lean roll-out processes according to the research dimensions constituting the framework. Findings – The effectiveness and the efficiency of the lean roll-out processes: first, negatively co-vary with the degree of lean knowledge codification; second, positively co-vary with the degree of autonomy of the plant; third, positively co-vary with the degree of contextual ambidexterity. Moreover, lean roll-out processes characterized by principles-based knowledge replication strategy, plant autonomy and contextual ambidexterity are comparatively more effective and efficient. Research limitations/implications – This is an exploratory qualitative study that develops propositions potentially testable in larger scale, more analytical research. Practical implications – This study provides a tentative roadmap to successfully approach the roll-out of lean production systems in complex organizations. Originality/value – This study challenges the current theory and practice which implicitly assumes that lean roll-outs take place linearly, cascading a set of predefined lean operations practices. Instead, the authors show that a less codified, more decentralized and contextually ambidextrous approach might be more effective.

To examine the relationships between supplier development practices and supplier-buyer relationship practices from the supplier’s perspective

2017 ◽  
Vol 24 (5) ◽  
pp. 1309-1336 ◽  
Author(s):  
Sarang Joshi ◽  
Manoj Kharat ◽  
Rakesh Raut ◽  
Sachin Kamble ◽  
Sheetal Kamble
Keyword(s):  
Structural Equation ◽  
Success Factors ◽  
Structural Model ◽  
Manufacturing Firms ◽  
Supplier Development ◽  
Competitive Advantages ◽  
Content Type ◽  
The Relationship ◽  
Relationship Improvement

Purpose The purpose of this paper is to examine the relationships between supplier development practices (SDPs) and supplier-buyer relationship practices from the supplier’s perspective (SBRSP), and seek to understand how specific SDPs may impact a buyer’s operational performance as well as supplier-buyer relationship practices. Design/methodology/approach The authors conducted a survey of 512 respondents from the different manufacturing firms in India and applied structural equation modelling to test a structural model that proposes the impacts of various efforts of SDPs on a buyer’s performance as well as SBRSP. Findings The study concludes that SDPs and SBRSP together improve the relationship between a buyer and supplier, and this improved relationship leads to competitive advantages (CAs) followed by profitability. Results indicate that supplier perspective of buyer-supplier relationship can be improved under the condition of SDPs and SBRSP together. SDPs are driven by productive measure and competitive pressure, whereas customer uncertainty is found to be statistically insignificant. Research limitations/implications The study was carried out in North Maharashtra Industrial Zone of India, where the auto sector and machine/components manufacturing firms have been established for a considerable period of time. Results of the study are limited to manufacturing organizations predominantly focussing on the automobile sector and machine/components manufacturing firms. Practical implications This study provides significant insights into the specific impact of various SDPs and SBRSP for both academics and practitioners. SDPs along with SBRSP practices lead to improvement in the relationship leading to CAs. SBRSP suggests that trust, long-term commitments and the supplier’s perspective are important practices for relationship improvement. Originality/value The current study attempts to identify what are the success factors for the supplier-buyer relationship from the supplier’s perspective and SDPs and how the supplier-buyer relationship can be improved under the condition of SDPs and SBRSP. Hence, the aim is to develop a more thorough understanding of the outcomes of a supplier-buyer relationship improvement from both buyer’s and supplier’s perspective, under the conditions of supplier development to achieve CAs leading to profitability. Furthermore, the study analyses the effect of the improved supplier-buyer relationship for achieving CAs leading to profitability.

Participative work design in lean production

2015 ◽  
Vol 27 (1) ◽  
pp. 19-33 ◽  
Author(s):  
Annika Lantz ◽  
Niklas Hansen ◽  
Conny Antoni
Keyword(s):  
Decision Making ◽  
Team Learning ◽  
Lean Production ◽  
Job Design ◽  
Learning Processes ◽  
Management Policy ◽  
Shop Floor ◽  
Content Type ◽  
Proactive Behaviour ◽  
The Relationship

Purpose – The purpose of this paper is to explore job design mechanisms that enhance team proactivity within a lean production system where autonomy is uttermost restricted. We propose and test a model where the team learning process of building shared meaning of work mediates the relationship between team participative decision-making, inter team relations and team proactive behaviour. Design/methodology/approach – The results are based on questionnaires to 417 employees within manufacturing industry (response rate 86 per cent) and managers’ ratings of team proactivity. The research model was tested by mediation analysis on aggregated data (56 teams). Findings – Team learning mediates the relationship between participative decision-making and inter team collaboration on team proactive behaviour. Input from stakeholders in the work flow and partaking in decisions about work, rather than autonomy in carrying out the work, enhance the teams’ proactivity through learning processes. Research limitations/implications – An investigation of the effects of different leadership styles and management policy on proactivity through team-learning processes might shed light on how leadership promotes proactivity, as results support the effects of team participative decision-making – reflecting management policy – on proactivity. Practical implications – Lean production stresses continuous improvements for enhancing efficiency, and such processes rely on individuals and teams that are proactive. Participation in forming the standardization of work is linked to managerial style, which can be changed and developed also within a lean concept. Based on our experiences of implementing the results in the production plant, we discuss what it takes to create and manage participative processes and close collaboration between teams on the shop floor, and other stakeholders such as production support, based on a shared understanding of the work and work processes. Social implications – Learning at the workplace is essential for long-term employability, and for job satisfaction and health. The lean concept is widely spread to both public bodies and enterprises, and it has been shown that it can be linked to increased stress and an increase in workload. Finding the potential for learning within lean production is essential for balancing the need of efficient production and employees’ health and well-being at work. Originality/value – Very few studies have investigated the paradox between lean and teamwork, yet many lean-inspired productions systems have teamwork as a pillar for enhancing effectiveness. A clear distinction between autonomy and participation contributes to the understanding of the links between job design, learning processes and team proactivity.

Job meaningfulness, employee engagement, supervisory support and job performance: a moderated-mediation analysis

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Abinash Panda ◽  
Subhashis Sinha ◽  
Nikunj Kumar Jain
Keyword(s):  
Job Performance ◽  
Employee Engagement ◽  
Social Exchange ◽  
Structural Equation ◽  
Manufacturing Industry ◽  
Equation Modeling ◽  
Conservation Of Resources ◽  
Supervisory Support ◽  
Content Type ◽  
Job Meaningfulness

PurposeGuided by social exchange, broaden and build and conservation of resources theoretical perspectives, this study explores the moderated mediating role of supervisory support (SS) on the relationship between job meaningfulness (JM) on job performance (JP) through employee engagement (EE).Design/methodology/approachField data were collected from two hundred and nineteen executives and their thirty-eight supervisors of a large paint manufacturing industry through a time-lagged research design and was analyzed with partial least squares based structural equation modeling.FindingsFindings of this study indicate that JM mediated by EE contributes to JP, which means if an employee finds one's job meaningful, she/he is likely to be more engaged emotionally, psychologically and cognitively to deliver better JP. SS is also found to be salient as it moderates both direct and indirect relationships between JM and JP through EE.Research limitations/implicationsGeneralizability of the findings of this study should be done with caution. Though the study has time-laggard data from two different sources but missing longitudinal data restricts causality of relationships/findings.Practical implicationsThese findings are relevant for organizations given that organizational leaders can create a context, by appropriate job design and engaging work context that motivates employees to perform better in their jobs. Insights of this study will be useful for organizations to curate meaningful jobs for their employees and also groom leaders with requisite skills and competencies to help subordinates perform up to their potential.Originality/valueThis study is an attempt toward a better understanding of the interplay of JM, work engagement and SS on JP in a manufacturing set-up in India, which has not been hitherto examined in Indian context.

Workplace environment, employee satisfaction and intent to stay

2019 ◽  
Vol 31 (1) ◽  
pp. 268-284 ◽  
Author(s):  
Deepak Bangwal ◽  
Prakash Tiwari
Keyword(s):  
Job Satisfaction ◽  
Employee Satisfaction ◽  
Structural Equation ◽  
Hospitality Industry ◽  
Hotel Industry ◽  
Intent To Stay ◽  
Equation Modeling ◽  
Workplace Design ◽  
Design Features ◽  
Content Type

PurposeThe hotel industry suffers from retaining its employees, and to retain their employees is a big challenge to the hotel industry. So, the purpose of this study is to examine the causal relationship between workplace design features of hospitality industry with employee job satisfaction and their intent to stay through empirical validation.Design/methodology/approachAs per the objective of the study, three hypotheses were proposed based on a comprehensive literature review on workplace design features of the hospitality industry. The proposed relationships were examined by using structural equation modeling approach with AMOS 18 as prescribed by Hair et al. (1998).FindingsSignificant evidence was found in favor of proposed hypotheses. The result of hypothesis testing showed workplace design features of hospitality industry to positively influence employee’s intent to stay through job satisfaction.Originality/valueWhile the employee satisfaction and commitment has been a significant research topic for more than decades, barely any research has been conducted that focuses specifically on workplace design features of a hospitality industry. This study tries to make a link between workplace design with the employee intent to stay through employee satisfaction. These links are rare from an Indian perspective.

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