Implementation of lean manufacturing and situational leadership styles

2017 ◽  
Vol 38 (7) ◽  
pp. 946-968 ◽  
Author(s):  
Guilherme Tortorella ◽  
Flávio Fogliatto
Keyword(s):  
Leadership Styles ◽  
Lean Manufacturing ◽  
Leadership Behaviors ◽  
Implementation Process ◽  
Hierarchical Level ◽  
Lean Implementation ◽  
Content Type ◽  
Clear Vision ◽  
The Matrix ◽  
The Moment

Purpose The purpose of this paper is to determine leadership styles at each hierarchic level that best support the LM implementation process in a given company. Design/methodology/approach To achieve that, the authors propose a method that combines information from two sources in three major steps. First, using opinions from experts on lean implementation from an activity sector of interest the authors determine leadership styles that best suit each phase of the LM roadmap for that sector. Next, the authors analyze a specific company within the activity sector to determine: at which lean roadmap phase the company is at the moment; and the style of its current leaderships at each hierarchical level. Finally, the authors combine information from previous steps to diagnose the suitability of company’s leaderships to its lean implementation needs. Findings The method points at improvement alternatives that may be developed simultaneously at different leadership hierarchical levels in companies. Further, using the matrix of ideal leadership styles, companies may be able to identify implementation phases in the lean process that are poorly served by current leadership styles, anticipating problems and developing HRM practices to mitigate them. That is quite relevant, since changes in leadership behaviors and expectations may take longer time to be implemented; therefore, it is important to understand these opportunities and have a clear vision of current gaps within the company. Originality/value The identification of leaderships’ attributes and behaviors in companies at different phases of the lean implementation roadmap contributes to the existing body of knowledge on lean manufacturing. The method is intended as a supporting tool for lean implementation, as it enables the assessment of gaps in leadership behaviors in the organization, and directs to improvements according to the phase of lean implementation. The goal is to complement existing lean roadmaps by driving improvements in leadership-related aspects of the implementation process.

Lean manufacturing implementation: leadership styles and contextual variables

2018 ◽  
Vol 38 (5) ◽  
pp. 1205-1227 ◽  
Author(s):  
Guilherme Luz Tortorella ◽  
Diego de Castro Fettermann ◽  
Alejandro Frank ◽  
Giuliano Marodin
Keyword(s):  
Leadership Styles ◽  
Lean Manufacturing ◽  
Leadership Behaviors ◽  
Evolutionary Process ◽  
Task Orientation ◽  
Least Squares Regression ◽  
Contextual Variables ◽  
Multiple Perspectives ◽  
Lean Implementation ◽  
Content Type

Purpose The purpose of this paper is to understand how the association between leadership styles (task or relation orientation) and lean manufacturing (LM) implementation changes due to two contextual variables, team size and the leader’s age. Design/methodology/approach The authors carried out a survey with 225 leaders from different Brazilian companies that are implementing LM. Research constructs were validated through rigorous procedures using confirmatory factor analysis. Hypotheses were tested using ordinary linear least squares regression. Findings The results suggest that larger teams and more senior managers were negatively associated with LM implementation. Task-orientation style makes leaders more likely to achieve higher levels of LM than relation-orientation style leaders. Finally, the influence of relation-oriented leaders on LM implementation is contingent upon the size of the team. Research limitations/implications Regarding study’s limitations, sample size and respondents’ location restrict results to this contextual condition, indicating that increasing the sample would help provide wider and more generalizable results. It is also worth noting that results are based on respondents’ (leaders) perspective. Hence, future studies may collect data from multiple perspectives, such as leaders and their followers, in order to compare results so as to verify the convergence or divergence among different respondents. Practical implications The results suggest that leaders should have different behaviors according to the context in which they are inserted. Therefore, such behavioral prescriptions are useful for managers since they are pressured to achieve high operational performance in short time periods and with few resources. Further, companies undergoing lean implementation may also be able to stimulate proper leadership behaviors and promote development programs accordingly, which is extremely relevant since behavioral changes usually take time. Originality/value The evolutionary process for achieving a successful lean enterprise requires different leadership styles according to the context in which leaders are inserted. This research provides arguments to help better understand the recommended leadership behaviors for lean implementation, complementing existing roadmaps by considering the proper leadership style as a contingency issue during lean implementation. Moreover, identifying the effect of contextual variables helps specify the contexts in which lean practices are more likely to be implemented.

scholarly journals Measuring lean implementation for maintenance service companies

2016 ◽  
Vol 7 (1) ◽  
pp. 35-61 ◽  
Author(s):  
Stephan J. de Jong ◽  
Wouter W.A. Beelaerts van Blokland
Keyword(s):  
Transaction Cost ◽  
Discrete Event Simulation ◽  
Continuous Improvement ◽  
Lean Manufacturing ◽  
Discrete Event ◽  
Asset Specificity ◽  
Lean Implementation ◽  
Content Type ◽  
Event Simulation ◽  
Maintenance Service

Purpose – Implementation of lean manufacturing is currently performed in the production industry; however, for the airline maintenance service industry, it is still in its infancy. Indicators such as work in process, cycle time, on-time performance and inventory are useful indicators to measure lean implementation; however, a financial economic perspective taking fixed assets into consideration is still missing. Hence, the purpose of this paper is to propose a method to measure lean implementation from a fixed asset perspective for this type of industry. With the indicators, continuous improvement scenarios can be explored by value stream discrete event simulation. Design/methodology/approach – From literature, indicators regarding asset specificity to measure lean implementation are found. These indicators are analysed by a linear least square method to know if variables are interrelated to form a preliminary model. The indicators are tested by value stream-based discrete event simulation regarding continuous improvement scenarios. Findings – With the new found lean transaction cost efficiency indicators, namely, turnover, gross margin and inventory pre-fixed asset (T/FA, GM/FA and I/FA, respectively), it is possible to measure operation performance from an asset specificity perspective under the influence of lean implementation. Secondly, the results of implementing continuous improvement scenarios are measured with the new indicators by a discrete event simulation. Research limitations/implications – This research is limited to the airline maintenance, repair and overhaul (MRO) service industry regarding component repair. Further research is necessary to test the indicators regarding other airline MRO service companies and other sectors of complex service industries like health care. Practical implications – The lean transaction cost efficiency model provides the capability for a maintenance service company to simulate the effects of process improvements on operation performance for service-based companies prior to implementation. Social/implications – Simulation of a Greenfield process can involve employees with possible changes in processes. This approach supports the adoption of anticipated changes. Originality/value – The found indicators form a preliminary model, which contributes to the usage and linkage of theories on lean manufacturing and transaction cost theory – asset specificity.

scholarly journals Lean-excellence business management for manufacturing SMEs focusing on KRI

2019 ◽  
Vol 69 (3) ◽  
pp. 519-539 ◽  
Author(s):  
Ibrahim Salih Mohammad ◽  
Chike F. Oduoza
Keyword(s):  
Lean Manufacturing ◽  
Business Performance ◽  
Small Firms ◽  
Assessment Model ◽  
External Support ◽  
Self Assessment ◽  
Implementation Framework ◽  
Lean Implementation ◽  
Content Type ◽  
National Quality

Purpose The purpose of this paper is to develop an effective framework for implementing Lean strategies in small- and medium-sized enterprises (SMEs) in the Kurdistan Region of Iraq (KRI). Design/methodology/approach Based on the integration of LM tools and techniques with the Malcolm Baldrige National Quality Award (MBNQA) criteria a systematic Lean implementation framework for manufacturing SMEs has been proposed. The core values, drivers and tools of the proposed framework were further developed based on case studies in three SMEs in the KRI. Findings Proposed framework is able to provide a simple pathway for SMEs to systematically implement Lean techniques in seven functional areas in order to create Lean culture in the organisation. Business performance measurement in terms of profitability, customer satisfaction, employee’s satisfaction, competitiveness growth and ergonomic improvement is presented in favour of evaluating Lean outcomes appropriately. It also presents the experience of small firms in implementing Lean programmes to show that Lean is valid in SMEs. Research limitations/implications The framework concentrates only on the internal issues of the organisation, while external variables such as national culture and external support are excluded. Practical implications The framework assists improvements in SMEs that either initially attempt to start Lean journey or those that are at more advanced levels towards excellent-Lean manufacturing. The framework can also be used as a self-assessment model to determine the degree of Lean readiness. Originality/value To the best knowledge of the author, it is the first framework that integrates Lean techniques with MBNQA criteria to support Lean implementation in SMEs. It is also the first study regarding Lean-excellence in the KRI.

RFID impacts on barriers affecting lean manufacturing

2016 ◽  
Vol 116 (8) ◽  
pp. 1585-1616 ◽  
Author(s):  
Muhammad Zeeshan Rafique ◽  
Mohd Nizam Ab Rahman ◽  
Nizaroyani Saibani ◽  
Norhana Arsad ◽  
Waqar Saadat
Keyword(s):  
Literature Review ◽  
Inventory Control ◽  
Systematic Literature Review ◽  
Lean Manufacturing ◽  
Shop Floor ◽  
Lead Times ◽  
Top Management ◽  
Rfid Technology ◽  
Lean Implementation ◽  
Content Type

Purpose Lean manufacturing is one of the leading paradigms for fast and proficient manufacturing but its proper implementation is a foremost task due to certain barriers affecting lean and can be handled when utilized with RFID technology. With this aspect in view, the purpose of this paper is to enlighten and present a thorough literature study that can show how RFID-based lean manufacturing is helpful for handling barriers affecting lean manufacturing in light of previous literature available. Design/methodology/approach In order to achieve this purpose a systematic literature review is conducted to justify the impacts of RFID technology for handling barriers. The aim of this systematic literature review is to initially find the barriers affecting lean implementation and then to explain the properties of RFID-based lean manufacturing which are highly feasible to handle detected barriers. Findings An interrelation is generated in this study which provides a clear indication that the properties of RFID carry significant effects to handle detected barriers in the operational, managerial and financial regime of manufacturing companies. The detected barriers that affect lean implementation are company’s cultures, top management commitment, poor employee administration, lack of finances, unbalanced inventory control, unstable customer handling and longer lead times. The properties of RFID-based lean manufacturing like operational visibility, inventory control, production control, minimized lead times and the real-time data information (to facilitate top management and employees on shop floor) are extremely helpful to control these barriers. Originality/value The originality of this study is the provision of clarity provided to both academicians and practitioners by citing and utilizing previous research studies which undoubtedly indicates positive impacts of RFID on lean implementation.

Fluid leadership in dynamic contexts

2015 ◽  
Vol 21 (1) ◽  
pp. 98-113 ◽  
Author(s):  
Christopher H. Thomas ◽  
Andrew S. Hebdon ◽  
Milorad M. Novicevic ◽  
Mario J. Hayek
Keyword(s):  
Leadership Styles ◽  
Leadership Style ◽  
Leadership Behaviors ◽  
Qualitative Comparative Analysis ◽  
Leadership Role ◽  
Repeated Treatment ◽  
Organizational Leaders ◽  
Theoretical Frameworks ◽  
Content Type ◽  
Effective Leader

Purpose – The purpose of this study is to examine an historical account of an effective leader who was able to draw from multiple styles of leadership, and choose a dominant style based upon contextual constraints and demands context, and subordinate behaviors associated with leadership styles not suited to the context. Design/methodology/approach – To identify his prominent style at each leadership episode, we critically analyzed Nehemiah’s leadership role transitions across 13 chapters of text using sociohistorical method and a quasi-repeated treatment design via qualitative comparative analysis. Findings – We found that Nehemiah adapted his behaviors such that his prominently displayed leadership style varied based on dynamic configurations of demands placed on him during his rebuilding efforts. As Nehemiah progressed through distinct stages of his mission, he differentially emphasized tactics associated with different styles of leadership in response to the contextual demands that were most salient during each stage. Practical implications – Organizational leaders are presented with evidence that developing a broad repertoire of leadership behaviors is essential to guiding followers within dynamic environments. Originality/value – This paper uses a novel historical source material to investigate contemporary leadership concepts grounded in established theoretical frameworks. Using this material, we demonstrate the applicability of various leadership styles within different contexts, and use Nehemiah as an illustration of an effective leader capable of fluidly enacting multiple leadership styles.

Performance evaluation of lean manufacturing implementation in Brazil

2014 ◽  
Vol 63 (5) ◽  
pp. 529-549 ◽  
Author(s):  
Wagner Cezar Lucato ◽  
Felipe Araujo Calarge ◽  
Mauro Loureiro Junior ◽  
Robisom Damasceno Calado
Keyword(s):  
Lean Manufacturing ◽  
Best Practice ◽  
Industrial Sector ◽  
Individual Element ◽  
Manufacturing Companies ◽  
Lean Implementation ◽  
Content Type ◽  
Lean Principles ◽  
Lean Practices ◽  
Survey Results

Purpose – Manufacturing companies worldwide have been replacing traditional mass-production practices by lean initiatives. This translation process is progressive and may vary depending on several factors. Hence, it could be expected that the degree of adoption of the lean practices could vary significantly among industries, regions and even countries. The purpose of this paper is to explore the implementation performance of lean principles in Brazil, the paper developed a survey in the Sao Paulo Metropolitan Area, which considered 51 industries of different sizes, from several industrial segments, nationals and multinationals. Design/methodology/approach – The proposed survey was developed using as a normative framework the SAE J4000 standard – identification and measurement of the best practice in implementation of lean operation and the SAE J4001 – implementation of lean operation user manual. To measure the implementation degree of the lean practices in the researched industries, the paper proposed the utilization of two concepts: the degree of leanness (DOL) of an element of J4000 and DOL of a company. Also three hypotheses were tested, trying to establish the relationship among the DOL and firm ownership, their size and respective industrial sector. Findings – The results obtained in the survey demonstrated that the performance of lean initiative implementation is not uniform among the companies located in the researched area. Outcomes also showed that the degree of implementation of the lean practices by multinational companies was higher than that for the national firms. However, it was not possible to establish a relationship between the DOL and the size of the firms. Neither a clear and definite association between DOL and industrial sector was possible to be identified. Practical implications – For the practitioners and managers dealing with the lean implementation, this paper gives a relevant contribution because it shows how they can effectively use an existing tool to measure the implementation of the lean practices in their respective firms. Furthermore, the DOL calculation for each individual element of the J4000 standard could also be used by practitioners and managers to identify specific problems and opportunity areas where practical actions could be identified to improve the lean implementation. Originality/value – This paper contributes to the lean manufacturing theory because it proposes a theoretical way to measure the degree of implementation of the lean initiatives in the manufacturing companies. Also the survey results generate additional research material that could be used by other researchers to further explore the subject in the area.

The relevance of intervention participants’ process appraisal for change in well-being and lean work processes of entire teams

2016 ◽  
Vol 3 (4) ◽  
pp. 376-394 ◽  
Author(s):  
Désirée Füllemann ◽  
Annemarie Fridrich ◽  
Gregor James Jenny ◽  
Rebecca Brauchli ◽  
Alice Inauen ◽  
...  
Keyword(s):  
Implementation Process ◽  
Participation Rate ◽  
Well Being ◽  
University Hospital ◽  
Outcome Expectancy ◽  
Work Processes ◽  
Lean Implementation ◽  
Content Type ◽  
Process Indicators ◽  
Monitoring Process

Purpose The purpose of this paper is to investigate whether intervention participants’ process appraisals relate to change in well-being and lean outcomes of entire teams. For this purpose, the study focussed on two main characteristics of a lean implementation process – workshop quality and outcome expectancy – and their interaction with the participation rate, and examined their association with leaner work processes and affective well-being in nursing teams. Design/methodology/approach Data were collected from a lean implementation project within 29 nursing wards of a university hospital. Employee surveys covering lean work processes and affective well-being at work were conducted before the implementation of four-day lean workshops in each nursing ward and six months after. The participating employee representatives evaluated the workshop quality and outcome expectancy of the workshops. Findings Multilevel analyses indicated that workshop quality did not relate to leaner work processes, but was associated with enhanced affective well-being after six months. By contrast, outcome expectancy was associated with leaner work processes, but did not relate to well-being. No moderation effects with participation rate were found. Practical implications The study shows the importance of monitoring process indicators in the early stages of implementation and optimising workshop contents and formats accordingly to ensure positive outcomes for entire teams. Originality/value The present study considers intervention participants’ process appraisals of workshop quality and outcome expectancy as good indicators of future change in lean work processes and the well-being of entire teams.

scholarly journals An implementation of lean manufacturing technology in enhancing efficiency in garment manufacturing industry with small and medium size

2021 ◽  
Vol 4 (1) ◽  
pp. first
Author(s):  
Hiền Ngọc Đỗ ◽  
Quỳnh Lam Ngọc Lê
Keyword(s):  
Case Studies ◽  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Implementation Process ◽  
Manufacturing Technology ◽  
Working Environment ◽  
Medium Size ◽  
Lean Implementation ◽  
Efficiency And Effectiveness ◽  
Enhance Efficiency

Lean manufacturing technology has been applied in industry to eliminate wastes, enhance efficiency and increase competition ability. While some case studies were evaluated successfully, others faced with big challenges. Actually, lean was applied in different ways due to types and size of industry or organization. This paper would present an lean implementation process, in which lean tools are integrated in simultaneously. Requirements on system manufacturing capacity should be met, so necessary resources would be determined. Manufacturing layout and work flows would be created smoothly. The lean implementation process was applied in some case studies in garment industry with small and medium size, which show the efficiency and effectiveness of the lean technology in the practice systems. The research shows the good results on some performance key indexes such as productivity, ability to satisfy the orders and good working environment.

Reckoning with the barriers to Lean implementation in Northern Indian SMEs using the AHP-TOPSIS approach

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Sachin Saini ◽  
Doordarshi Singh
Keyword(s):  
Lean Manufacturing ◽  
Large Scale ◽  
Service Sector ◽  
Extensive Study ◽  
Small Scale ◽  
Successful Implementation ◽  
Topsis Method ◽  
Lean Implementation ◽  
Content Type ◽  
The People

Purpose The purpose of this study is to recognize critical barriers for Lean manufacturing practices implementation in small and medium enterprises (SMEs) focusing in the context of a developing economy. The advancement of SMEs is of utmost important for a surge in exports while competing with other countries and these barriers have to be given due importance as they play a major role in stalling the overall development of SMEs. Design/methodology/approach In this present investigation, 26 barriers to Lean implementation in SMEs have been identified after an extensive study of the literature available on the subject. After that, the influential barriers were investigated through the Analytical hierarchy process-Technique of order preference by similarity to ideal solution (AHP-TOPSIS) method using priority weightage given to them by different experts in their industries. The ranking given to the barriers is based on the AHP-TOPSIS method and has been validated by the sensitivity analysis. Findings The investigation reveals that for the successful implementation of Lean manufacturing practices, the will of the management, individual will power and contribution of the people matter a lot apart from other barriers such as flexibility, expertise of the people, resources and resistance offered by the people to new programs. The solutions for overcoming these barriers are also provided in this study and a model has been suggested for the same. Research limitations/implications This work was devoted to the evaluation of obstacles in the introduction of Lean practices and prioritizing them. But it was limited to the medium- and small-scale organizations located in Northern India. Further studies can expand the scope to the large-scale units in the field. Moreover, the scope of this study was confined to the manufacturing sector. Future studies can extend it to the non-manufacturing environments such as the service sector, health care, etc. This investigation was based on the judgments of industry experts and academicians. Another approach such as Viekriterijumsko kompromisno rangiranje can be used for future investigations. Originality/value This study is significant when keeping in mind the contribution of SMEs to a country’s economy, especially in the Indian context.

Lean implementation in small- and medium-sized enterprises

2018 ◽  
Vol 25 (4) ◽  
pp. 1121-1147 ◽  
Author(s):  
Saumyaranjan Sahoo ◽  
Sudhir Yadav
Keyword(s):  
Lean Manufacturing ◽  
Management Practices ◽  
Practical Implication ◽  
Performance Criteria ◽  
Research Approach ◽  
Lean Implementation ◽  
Content Type ◽  
Positive Effects ◽  
Lean Tools ◽  
And Performance

Purpose The purpose of this paper is to examine the extent to which lean management practices are adopted by small- and medium-sized manufacturing organizations in India and their impact on firm’s operational performance (OP). Also, the paper makes an attempt to identify the barriers and challenges faced by Indian SMEs that are striving to succeed with improvement efforts based on lean manufacturing. Design/methodology/approach In this paper, acceptability and implementation of lean manufacturing in Indian Manufacturing SMEs were analyzed using three constructs, namely, process improvement (PI), flow management (FM) and waste minimization (WM). The responding firms were categorized into “lean-Beginners,” “In-transition lean” and “lean” group based on their phases of lean implementation. Using a survey questionnaire, data were collected from 121 manufacturing SMEs in India. Lean tools and barriers, identified from the literature review, were also included in the survey. The reliability and validity of the practice and performance measures were evaluated. Correlation analysis was employed to investigate the effects of three constructs on OP. Findings The results indicate that all the three lean constructs are significantly related to OP. In the context of Indian manufacturing SMEs, “PI” and “WM” practices have shown a higher level of significance on OP, compared to “FM” practices. “5S -workplace organization” was found to be the most practiced lean tool. “Attitude of workmen” was highlighted as the main obstacle in successfully implementing lean. The findings suggest overall positive effects as a result of applying lean tools and philosophy in Indian SMEs. Research limitations/implications The research results may lack qualitative justification because of the chosen research approach. Therefore, the researchers are encouraged to explore the inter-relationship among various lean tools/practices and performance criteria by conducting a qualitative study in the form of a case study or action research. Practical implications This paper is a beneficial source of information that highlights the contribution of lean implementation in enhancing manufacturing productivity. The major tools and techniques used by Indian SMEs have been highlighted and discussed; it could be a genuine source of motivation to lean practitioner and entrepreneurs of SMEs to go in for lean implementation. The findings are also expected to benefit the lean practitioners and entrepreneurs of SMEs to focus on vital issues to facilitate successful lean implementation in an organization. Originality/value The paper demonstrates that practical implication of lean implementation can bring real breakthroughs in productivity to small- and medium-scale manufacturing firms.

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