Structural Equation Modelling based Empirical Analysis of Technological Factors for Lean Implementation (original) (raw)
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Management Science Letters, 2018
The purpose of this paper is to explore and integrate the role of human resources with the internal practices of the Indian manufacturing industries towards successful implementation of lean manufacturing (LM). An extensive literature survey is carried out. An attempt is made to build an exhaustive list of all the input manifests related to human resources and internal practices necessary for LM implementation, coupled with a similar exhaustive list of the benefits accrued from its successful implementation. A structural model is thus conceptualized, which is empirically validated based on the data from the Indian manufacturing sector. Hardly any survey based empirical study in India has been found to integrate human resources with the internal processes towards successful LM implementation. This empirical research is thus carried out in the Indian manufacturing industries. The analysis reveals six key input constructs and three output constructs, indicating that these constructs should act in unison to maximize the benefits of implementing lean. The structural model presented in this paper may be treated as a guide to integrate human resources with internal practices to successfully implement lean, leading to an optimum utilization of resources. This work is one of the very first researches to have a survey-based empirical analysis of the role of human resources and internal practices of the Indian manufacturing sector towards an effective lean implementation.
Lean philosophy has an important role to play in today's competitive globalised market which is mainly governed by fickle requirement of market, rapid change and advancement in technology, quality, profit, cost reduction and higher expectations of customer. As world has witnessed that implementation of lean concepts in industries has resulted into enhanced productivity, better quality, higher profit, better customer satisfaction, sense of achievement in employees, better employee and employer relation, sense of belonging towards their work. In spite of these advantages lean philosophy has not caught the attention and imagination of top management in all kinds of industries for e.g. SMEs, service industries, system engineering and product development. The main reason of non-implementation of lean concepts can be attributed to various obstacles or barriers being faced by industries. Earlier research indicates that few of the barriers are known to the environment and attempts have also been made by researchers and experts in lean philosophy to establish a relationship between these barriers. In this paper the aim is the correct identification and confirmation of barriers of lean implementation in present scenario and establishing a relationship between them. It is also important to come out with the strategies to overcome the identified obstacles faced by industries in implementing lean philosophy. The approaches in this paper used are firstly in-depth knowledge of subject inanalysis by literature review, secondly by means of a comprehensive questionnaire circulated to various industries to collect the qualitative data, and lastly to validate the data and to derive the inferences.
Today, principles and practices of Lean manufacturing are widely used by industries to eliminate waste and make the process more efficient. Lean has been recognized as one of the key approaches in enhancing the productivity and hence the competitiveness of an organization. This paper presents a review of lean principles and practices in the Indian manufacturing industries. The paper contributes by identifying enablers & barriers in implementing the lean principles and practices, methodologies used in leanness measurement of an organization in the Indian manufacturing industry. Finally, the diffusion of lean in the Indian manufacturing industries has been given.
Lean Implementation in Manufacturing Industries: Benefits and Shortcomings
International Journal of Recent Trends in Engineering and Research, 2017
Manufacturing industries require continuous improvement process to perform better and withstand the intense global competition. Lean manufacturing or lean production is one of the most popular paradigms in process improvement. Lean philosophy is implemented by organizations worldwide but its implantation is snail-paced in India and needs to be augmented. Based on a systematic literature review and by performing a case study on lean implementation, this paper presents a detailed analysis of lean philosophy in manufacturing industries. Numerous benefits and shortcomings associated with lean implementation are explained in this paper. This paper presents the case studies on lean implementation performed by researchers over the years using various tools and methodologies for the review and understanding of most effective lean tools, benefits and shortcomings of lean production system (LPS). The authors have performed and presented a case study on lean implementation in a manufacturing industry to realize its benefits and shortcomings. The proposed work provides required preliminary information for lean implementation in manufacturing industries. Factors that hinder lean implementation are identified which must be sorted for successful implementation of lean principles in any manufacturing organization.
Analysis of Barriers to Lean Implementation in Machine Tool Sector
Acute global competition has forced organization to adopt Lean manufacturing strategy in order to improve competitive potential. Top managements should examine the barriers to lean in order to ensure its effective implementation. This paper aims to analyze the barriers to implementing lean manufacturing practices based on the investigation of machine tool industry in the National Capital Region of India. Two distinct modeling approaches namely Interpretive Structural Modeling (ISM) and Interpretive Ranking Process (IRP) have been employed to examine the contextual relationship among the lean implementation barriers, and to rank them with reference to key performance areas, respectively. Lean implementation barriers and performance indicators were identified through literature review and opinion of experts from industry and academia. ISM methodology is used to understand the mutual influences among the lean barriers and then classify these barriers on the basis of their driving and dependence powers. As is obvious, the barriers with high driving power and dependency need more attention than the others. Development of a structural model for barriers to lean implementation can be considered as one of the major contribution of this study. The novel IRP methodology is used to examine the dominance relationship and ranks the barriers with respect to key performance indicators related to the machine tool industry.
A SURVEY ON THE ADOPTION OF LEAN PRACTICES IN INDIAN MANUFACTURING SECTOR
IAEME Publication, 2016
Lean manufacturing is a production strategy to eliminate waste and nonvalue added activities in a process while maximizing the value added tasks as required by the customer. The adoption of lean approaches in India has been much slower. Indian industries find many challenges in adopting lean thinking as a standard manufacturing practice. it has been proved from certain studies that implementation of lean thinking in manufacturing sector is highly useful in terms of elimination of waste, proper utilization of workspace, proper organization of workforce, to reduce inventory, to increase productivity and to increase customer satisfaction. This study will guide the Indian industries in selecting lean tools based on the characteristics and expected wastes. The current study comprise of a survey of Indian manufacturing industries. The survey will be useful to explore the current status of lean initiations in Indian manufacturing industries and to prioritize lean practices which are highly useful.
Implementing lean manufacturing system: ISM approach
Journal of Industrial Engineering and Management, 2013
Purpose: Lean Manufacturing System has emerged as an important area of research in Indian context. The requirement of Lean Manufacturing has increased due to defects in products (semi finished and finished) and subsequent increase in cost. In this context, this study is an attempt to develop a structural model of the variables, important to implement Lean Manufacturing System in Indian automobile industry.
Lean Manufacturing in Indian Industries A Review
2013
The purpose of this research is to first identify the critical lean manufacturing factors responsible for implementation of lean manufacturing in the Indian manufacturing sector and then to incorporate these factors into a framework, which can be represent the present status of lean practices in Indian industries. Also to identify barrier and benefits of lean manufacturing in industries. The approach of the research includes a literature review, in-depth interviews and questionnaire surveys. The most important criteria of lean manufacturing are identified through an extensive survey conducted in manufacturing industries encompassing various fields like engineering, automobile, processing and others. Statistical Package for the Social Sciences (SPSS) software is used for checking the reliability and validating the obtained results in order to incorporate both tangible and intangible criteria of lean manufacturing practices.
Lean Implementation in Indian Foundry Industries: A Quantitative Survey
The implementation of Lean and the deciding parameters are elaborately studied by surveying the Indian Foundry industry workers. The study conducted in the domain of various demographical factors of age, firm size, education background, gender and years of experience shows cluttering of the data indicating the reasons, benefits and barriers of Lean implementation in Indian sub-continent. 28 Foundry Industries in the state of Karnataka are surveyed with a total of 204 workers providing the input for the intricate questionnaire designed for them. The results indicate that the factors like overall equipment effectiveness, plan-do-check-act, total productive maintenance, bottleneck analysis, continuous flow manufacturing, poka yoke, and standardized work are the most effective categories of Lean. The same is also evident from the standard deviation values obtained from chi-square distribution
ijRnDESM, 2019
Lean Manufacturing Model has arisen as a major field in Indian science. Due to commodity shortcomings (semi-finished and finished) and consequent cost increases, the need for Lean Manufacturing has increased. Specific variables of the application of Lean Manufacturing program from the literary analysis and perspectives of experts have been established. After the brainstorming session, the relationship between these variables was created. In order to evaluate these variables rate, a questionnaire-based survey was also performed. Clear understanding of relationships among these variables allows companies to evaluate, control and execute these variables more efficiently and effectively. In this sense, this analysis is an attempt to develop a systemic model of the important variables in Indian automobile industry for the implementation of Lean Manufacturing Model. After the brainstorming session, the relational relationship between these defined variables was established.In fact, analysis of variables dependent on moving force and dependency has been carried out. In fact, an Indian Automotive Conceptual Modeling (ISM) methodology has been used to build a conceptual model of variables for applying the Lean Theory. These variables were also ranked in a questionnaire-based survey. In the literature eighteen variables and subsequent discussions with experts have been identified. Ten variables were classified as reactive and ten were defined as passengers. The relation variable and the autonomous variable were not known. Relative cost benefits' were defined as the highest dependent variable and the highest management engagement as the lowest independent variable from the model created. The developed model is a theory based on the opinions of experts. In actual circumstances, the conclusions therein made may be further amended. Clear understanding of the relationships between these factors can enable companies identify these variables and handle them more effectively and take advantage of the introduction of the lean manufacturing method.