Sustaining factors for lean manufacturing excellence : an explanatory mixed methods study

In today's market, manufacturers face challenges in quality, flexibility, costs, and productivity. To stay competitive, the manufacturing industry must enhance processes to maximize value and reduce waste. Therefore, lean manufacturing implementation is crucial for survival in today’s competitive market. However, figures indicate that not all manufacturers have effectively implemented lean practices to improve their organizational performance. This sequential explanatory mixed methods study aims at investigating the sustaining factors of lean manufacturing implementation among medium and large discrete manufacturers in Malaysia while scrutinizing the role of manufacturing maturity in strengthening the effects of lean manufacturing implementation on manufacturing excellence. The result interpretation from quantitative and qualitative concluded that lean knowledge management, lean culture, lean leadership, lean supplier management strengthen lean manufacturing implementation, while lean resource management does not strengthen its implementation. The results indicate that initially, lean manufacturing implementation does not have a direct impact on reducing production costs. However, the effects become significant when the implementation mature along the learning curve. This study is hoped to expand the boundary of the existing literature and contribute to the body of knowledge while providing insights to practitioners in tailoring strategies to sustain lean manufacturing implementation and leverage their manufacturing excellence. As a recommendation for future researchers, it is suggested to investigate lean technology, integration of management systems, and research and development involvement as sustaining factors for lean manufacturing implementation

Save it for a rainy day! Lean strategies for cost saving: the role of lean maturity

Purpose: This study investigates the effect of lean implementation on production cost reduction and the moderating role of lean manufacturing maturity. Design/methodology/approach: This study employed a cross-sectional survey, of which the samples were drawn using a cluster sampling procedure from 151 middle and top-level management of medium and large manufacturing companies gathered from the Federation of Manufacturers Malaysia (FMM). Data were analyzed using the PLS-SEM approach through SmartPLS4 software. Findings: The result revealed that lean implementation does not leverage production cost reduction as the lean journey requires long-term orientation, which finally leads to valid cost reduction. The moderating role of lean manufacturing maturity was significant and positive in the relationship between lean manufacturing implementation and production cost reduction. Research limitations/implications: Future research should include longitudinal settings as this study is cross-sectional, and future research might put the present model to the test in multiple industries and regions, including a cross-country comparison to improve the generalizability of the findings. Additionally, further studies could extend this study using a mixed-method approach. Practical implications: By offering a holistic perspective, this study expands the existing literature, contributes to knowledge of integrated lean implementation and supports the management in planning their path towards cost-cutting performance. Originality/value: This study answers the inconclusive finding between lean implementation and operational performance in terms of production cost reduction. The study contributes to the body of knowledge and, most importantly, to the practitioners in planning their lean journeyPeer Reviewe

An Analytic Hierarchy Process Approach in Decision-Making for Material Selection in an Automotive Company: A Case Study

This study is an approach to investigate and to choose the suitable material for the fabrication of tools trolley to ensure the good quality of the product. The project team of an automotive manufacturing company is planning to fabricate 100 sets of tools trolley in the assembly shop. This study was developed to describe an approach based on Analytic Hierarchy Process (AHP) that can assist decision-makers and continuous improvement engineers in determining the most suitable material to be employed in fabrication process at the early stage of the product development to reduce the cost. The selected main criteria are Material Strength, Material Cost, Procurement Lead Time and Duration of Fabrication Process while the four materials that will be considered in this study are Aluminium, Steel Tube, and Square Tube. Finally, the results show that Square Tube is recommended as the most suitable material for the in-house tools for trolley fabrication

Movers and shakers: Leadership attributes for a successful lean manufacturing implementation

Purpose: This study aims to investigate the leadership attributes for successful lean manufacturing implementation. Design/methodology/approach: This study employed a case study in European automotive manufacturing plants through a series of interviews with six informants from four countries. The six informants represent each subgroup from the job responsibilities. Findings: The result comprises four main lean leadership attributes for successful lean manufacturing implementation. First, management commitment, involvement, and engagement, followed by management mission and vision. In addition, management coaching and effective communication were highlighted as important attributes of lean leaders. Research limitations/implications: Further studies could extend this study using a mixedmethod approach. Applying both methods will contribute significantly to providing a holistic view, providing a breadth and depth to understanding phenomena that neither qualitative nor quantitative research approaches alone could support. Practical implications: This study contributes to expanding the boundary of the existing literature and contributes to the body of knowledge while providing insights to practitioners in tailoring strategies to strategize the roadmap, ensuring the implementation is ongoing by integrating the leadership role to reap the maximum benefit of lean implementation. Originality/value: Although several studies presented positive relationships of leaders and the characteristics, skills, and behaviors of leaders that facilitate lean success from a case study, this study examines the leadership attributes from various contexts to facilitate a deeper comparative analysis

Lean culture for a successful lean manufacturing implementation: An empirical evidence from Malaysian manufacturing industry

Although lean has gained many accomplishments, 90% of the manufacturers that implemented lean failed to sustain the implementation, and these results have led academics to consider lean culture as a soft lean approach for successful lean implementation. This research is aimed to investigate the role of lean culture for a successful lean implementation. This survey-based was a cross-sectional study with 151 final respondents from discrete manufacturers in Malaysia. The samples were selected using a cluster sampling procedure from medium and large manufacturing companies registered with the Federation of Manufacturers Malaysia (FMM). The data was analyzed using SmartPLS 4.0 software. The result showed evidence that lean manufacturing implementation is positively impacted by lean culture. This study contributes to the body of knowledge and widens the bounds of the current literature, and offers insight to the lean practitioners on lean implementation techniques to strategize the roadmap and assure continuous execution by considering the role of lean culture

Sustenance strategies for lean manufacturing implementation in Malaysian manufacturing industries

This study aims to investigate the relationship between sustaining factors and lean manufacturing implementation.This survey-based study was a cross-sectional study and the samples were drawn by using cluster sampling procedure from medium and large manufacturing companies based on the Federation of Manufacturers Malaysia (FMM) with the final number of 151 respondents. In total, four hypotheses were developed and tested statically using PLS-SEM through SmartPLS software.The result provided evidence that lean culture, lean leadership, and lean knowledge management have a positive relationship on lean manufacturing implementation. However, lean supplier management does not have a positive relationship on lean manufacturing implementation.The survey was responded by middle and top-level management from the discrete manufacturing industries. Although there is growing interest in empirical shreds of evidence in favor of sustaining lean, this study provides a comprehensive view of sustaining factors for lean manufacturing implementation.Hence, this study contributes to expanding the boundary of the existing literature and contributes to the body of knowledge while providing insights to practitioners in tailoring strategies to sustain lean manufacturing implementation and leverage their performance

Save It For a Rainy Day! Lean Strategies for Cost Saving: The Role of Lean Maturity

Purpose: This study investigates the effect of lean implementation on production cost reduction and the moderating role of lean manufacturing maturity. Design/methodology/approach: This study employed a cross-sectional survey, of which the samples were drawn using a cluster sampling procedure from 151 middle and top-level management of medium and large manufacturing companies gathered from the Federation of Manufacturers Malaysia (FMM). Data were analyzed using the PLS-SEM approach through SmartPLS4 software. Findings: The result revealed that lean implementation does not leverage production cost reduction as the lean journey requires long-term orientation, which finally leads to valid cost reduction. The moderating role of lean manufacturing maturity was significant and positive in the relationship between lean manufacturing implementation and production cost reduction. Research limitations/implications: Future research should include longitudinal settings as this study is cross-sectional, and future research might put the present model to the test in multiple industries and regions, including a cross-country comparison to improve the generalizability of the findings. Additionally, further studies could extend this study using a mixed-method approach. Practical implications: By offering a holistic perspective, this study expands the existing literature, contributes to knowledge of integrated lean implementation and supports the management in planning their path towards cost-cutting performance. Originality/value: This study answers the inconclusive finding between lean implementation and operational performance in terms of production cost reduction. The study contributes to the body of knowledge and, most importantly, to the practitioners in planning their lean journey

Systematic Literature Review: Lean Ergonomics Analysis in Small & Medium Enterprises (SMEs) Manufacturing Sector

Ergonomics has emerged as a significant workplace issue, negatively impacting finances due to worker absence and reduced productivity. Small and Medium Enterprises (SMEs) are particularly prone to occupational accidents, contributing to over 80% of such incidents. This review delves into the perspective of lean ergonomics within SMEs. The study followed a structured review protocol, formulating research questions and systematically searching the Scopus and WoS databases. The findings reveal several key points: (1) SMEs commonly implement ergonomics principles addressing awkward postures, repetitive movements, manual material handling, hand-wrist postures, excessive reach, grip strength, and prolonged standing; (2) Lean principles such as SMED, 5S, standardized work, TPM, VSM, and kanban positively impact ergonomics; (3) Various ergonomics assessment methods, including REBA, RULA, HFE, JSI, KIM, OCRA, and Shoaf’s model, are recommended for future research and practical application; (4) Ergonomics can underpin lean transformation efforts, with Lean Manufacturing (LM) contributing to reduced ergonomics risks. However, the review identified a limitation in the scope of databases used (WoS and Scopus), suggesting that expanding the range of databases and research keywords could improve future article searches. The study's primary focus serves as a reference point for future researchers and manufacturers interested in lean ergonomics, emphasizing the need for comprehensive approaches to enhance worker safety and productivity through ergonomic and lean practices

Systematic literature review: Lean ergonomics analysis in small & medium enterprises (SMEs) manufacturing sector

Ergonomics has emerged as a significant workplace issue, negatively impacting finances due to worker absence and reduced productivity. Small and Medium Enterprises (SMEs) are particularly prone to occupational accidents, contributing to over 80% of such incidents. This review delves into the perspective of lean ergonomics within SMEs. The study followed a structured review protocol, formulating research questions and systematically searching the Scopus and WoS databases. The findings reveal several key points: (1) SMEs commonly implement ergonomics principles addressing awkward postures, repetitive movements, manual material handling, hand-wrist postures, excessive reach, grip strength, and prolonged standing; (2) Lean principles such as SMED, 5S, standardized work, TPM, VSM, and kanban positively impact ergonomics; (3) Various ergonomics assessment methods, including REBA, RULA, HFE, JSI, KIM, OCRA, and Shoaf’s model, are recommended for future research and practical application; (4) Ergonomics can underpin lean transformation efforts, with Lean Manufacturing (LM) contributing to reduced ergonomics risks. However, the review identified a limitation in the scope of databases used (WoS and Scopus), suggesting that expanding the range of databases and research keywords could improve future article searches. The study's primary focus serves as a reference point for future researchers and manufacturers interested in lean ergonomics, emphasizing the need for comprehensive approaches to enhance worker safety and productivity through ergonomic and lean practices

Towards sustainable lean success : A systematic literature review on critical failure factors

Lean manufacturing (LM) is a leading philosophy used by organizations to become inevitable in the challenging market. However, prior research showed evidence that 90% failure rate of LM within 10 years of implementation, hence this study is to undertake a systematic literature review on the failure of LM implementation. Design/methodology/approach: This study was conducted with the guidance by review protocol, research questions’ formulation, systematic searching based on identification, screening and eligibility using Scopus and Web of Science databases, quality appraisal, data exclusion and analysis. Findings: Derived from 15 sub-themes, five main themes were discovered based on the thematic analysis to answer the research question on “What strategies should manufacturers do to prevent the failure of LM implementation?”, namely (1) leadership, (2) culture, (3) knowledge, (4) resources and (5) suppliers. Research limitations/implications: WoS and Scopus were employed in this review, despite there are 14 databases with the ability to search for potential articles in them. Mixed-Method Appraisal Tool (MMAT) was used to evaluate the quality control process, however using various quality assessment techniques helps to search for appropriate review objectives. Practical implications: The primary emphasis of this study can be used as a reference by the manufacturers to ensure that LM implementation is a success story to gain a competitive advantage. Originality/value: Despite a large body of literature on LM, there has been little attempt to review this study in a systematic approach, discover trends and generate thematic potential on the failure factors of LM, making it difficult for academics to replicate and interpret