Strategies For The Successful Lean Manufacturing Implementation: A Case Study In A Malaysian Automotive Parts Manufacturing (original) (raw)
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2014
Lean manufacturing strategy is a well-known manufacturing approach that is acknowledged to be capable and effective towards achieving higher performance standards by limiting waste, improving manufacturing processes through continuous improvements and employee involvement and experiencing sustainable growth by creating synergistic value streams across a manufacturing environment. Implementations of lean manufacturing system within the automotive industry in Malaysia is not as far-reaching as expected and is currently being adopted as a pick-and-choose system and only being applied in certain stages and known areas. This approach does not allow these organizations to fully explore and exploit the system’s effectiveness; neither do they experience any massive improvements when measured against lean manufacturing success standards. However, factors affecting the lean manufacturing implementation in Malaysia is still seldom debated or being discussed in literature reviews. In this paper...
Barriers to Implement Lean Manufacturing in Malaysian Automotive Industry
Jurnal Teknologi, 2012
Implementing lean manufacturing in a developing country such as Malaysia is still considered to be a major challenge due to several barriers. It is essential for all managers to understand these barriers and try to minimize them and improve competition strength. The purpose of this study is to investigate the barriers of lean manufacturing in the automotive industry in Malaysia. A survey have been conducted and sent to 250 companies from automotive manufacturing plant and suppliers in Malaysia, giving a 20.8% response rate. The statistical package for the social science (SPSS) software was used to analyze the data from the surveys. The result shows that the lack of skilled is the highest obstacle implement lean and following by lack of awareness and company culture. Attempt was made at finding significance difference between small, medium and large companies on obstacle in lean implementation. The findings of this research provide invaluable information to all desire to implement le...
A survey on lean manufacturing implementation in Malaysian automotive industry
2010
Abstract—This paper presents an exploratory study of lean manufacturing implementation in Malaysian automotive industries. A questionnaire survey is used to explore the extent of lean manufacturing implementation. This paper also examines the drivers and barriers that influence the implementation of lean ma nufacturing. The survey was performed on sixty Malaysian automotive components manufacturing firms.
A STUDY ON LEAN MANUFACTURING IMPLEMENTATION IN MALAYSIAN AUTOMOTIVE COMPONENT INDUSTRY
Lean manufacturing is an extended version of the Toyota Production System (TPS). It was highlighted as the best practice in the 21st century. Therefore, top and senior management in manufacturing firms are encouraged to adopt and adapt lean principles and practices in running their respective firms. The main objective of this paper is to investigate the extent of lean manufacturing perception and implementation in the Malaysian automotive component industry. A survey questionnaire was developed to collect top and senior management views with respect to their perception, judgement and opinion on twenty four lean manufacturing (LM) practices. This preliminary survey was conducted at 30 Malaysian automotive component manufacturing firms. The survey results show that a large majority of respondents have a high perception of the importance of lean manufacturing practices. However, it was found that their actual LM implementation is still on the low side. In this study, the non-parametric test was used to analyze the level of perception and implementation of the twenty four LM practices. The analysis of the survey results revealed that there are significant differences between the level of perception of the importance of LM practices and their actual implementation.
Critical Success Factors for Implementing Lean Manufacturing in Malaysian Automotive Industry
The challenges faced by automotive manufacturers had made them looked into Lean Manufacturing (LM) which was implemented by Toyota Motor a long time ago. In Malaysia, the two main car manufacturers are PROTON and PERODUA; these two manufacturers offer good opportunity to large local companies and Small Medium Enterprises (SMEs) to participate in the automotive component manufacturing industry. The main objective of this study is to explore and investigate the level of perceptions on the importance and extent of practice with respect to 13 Critical Success Factors (CSFs) for LM implementation. To perform this study, a survey instrument that consists of 13 CSFs and 78 items was developed and distributed to local companies. The comparison was carried out on each of these CSFs based on perception, number of years and company size. The statistical analysis using the Kruskal Wallis test had identified four basic critical success factors for both SMEs and large companies with respect to the perception on the importance and extent of practice. Further study probes into the outcomes of the exploration on feasible LM practices.
Due to global competition, automotive component industries are very keen to improve their manufacturing system as to fulfill car manufacturer demand. Currently, lean manufacturing (LM) system has become increasingly famous and popular among automotive component players. And, it was proven that lean manufacturing is the best manufacturing system in the 21 st century. The main objective of this paper is to investigate the extent of 24 lean manufacturing practices implementation in SME. Secondly, to determine the possible barriers that could influence the process of lean manufacturing implementation. A survey questionnaire was developed to collect top and senior management judgement on 24 lean manufacturing practices and to rate the possible barriers during lean manufacturing implementation. Total completed questionnaires were 97 which represent 81.5% respond rate. The survey results show that a majority of respondents agreed and implementing extensively kaizen, 5S and standardization in their firms. Another finding was the four possible barriers that could influence the failure of lean manufacturing implementation which are employees resist to changes, unstable customer schedule, lack of knowledge and poor employee involvement.
A Full-Blown Concept of Lean Manufacturing System in Automotive Industry
Journal of Industrial and Intelligent Information
Lean manufacturing system (LMS) is not a novel concept to manufacturing and the automotive industry, but achieved implementations seen are still not considered industry-wide especially in the Malaysian automotive manufacturing industry. The implementation strategies have not been far reaching and the benefits from the system couldn't be gained by the industry. A total and comprehensive implementation strategy of LMS needs to be outlined in order to achieve more successful implementations. Thus this paper will explain the strategy of LMS implementation in the automotive industry by using the full-blown concept, for enhancing their organizational performances. A questionnaire-survey was administered to gauge the impact of these factors in an implementation process of lean manufacturing system and later analyzing the effect towards their organizational performances. Data from 204 automotive parts manufacturers were gathered and analyzed. The correlation between the 10 influencing factors, 5 lean activities and 6 organizational performances were measured. The results gained, suggest that the integration between the identified influencing factors (Management and Leadership Commitment, Employees Involvement, Empowerment of Employee, Teamwork, Training, Human Resource Management, Customer Relationship Management, Supplier Relationships Management, Organizational Change and Information Technology) will be a valuable key organizational capability impacting organizational performances towards the successful implementation of LMS in the Malaysian automotive industry.
The Challenges Of Lean Implementation: A Multiple Case Study In Malaysian Aerospace Companies
2017
The purpose of this study was to determine the challenges in implementing lean process in Malaysian aerospace companies. Literature indicated that some companies failed to achieve full lean benefit. This study adopted qualitative multiple case study as the methodology. Three main steps in the case study protocol were followed. The data was collected through semi-structured interviews of sixteen respondents from four different companies in the aerospace industry. Thematic analysis was conducted for every case together with the cross-case analysis. The results of this study verified that the companies faced resistance from the employees. However, lack of commitment from the top management to implement lean and the influence of local culture on the companies have excerbated the challenges of lean implementation. The output of the study could serve as a guide for the companies to strengthen their effort of enhancing the employees commitment to implement lean process
Critical success factors of lean manufacturing practices for the Malaysian automotive manufacturers
Lean manufacturing (LM) and ISO 14001 are business process strategies which are employed by the group of companies to enhance their production in manufacturing and business issues. LM focus on the systematic elimination of waste and non-value added activity from the production process for improved environmental performance. This pilot study was conducted to investigate critical success factors (CSFs) towards successful LMP implementation among automotive manufacturing industry in Malaysia. The questionnaires were designed and distributed to the 50 respondents. The results of reliability analysis show that customer focus is a critical factor influencing the direct LMP implementation success. This study recommends that the future research explore the influence of LMP on environmental performance in Malaysian automotive industry.
2015
Challenging and competitive business environment has prompted the automotive industry to restructure its manufacturing practices. Nowadays, Lean Manufacturing (LM) has been widely implemented in the automotive industry. LM supported the manufacturing companies, particularly automotive manufacturers in becoming world class manufacturers through various lean practices. However, lean implementation faced various obstacles such as the lack of management commitment and support, the absence of organizational communication, employees’ attitude and many more. It is also indicated that lean implementation success factors are not merely due to technical practices but also with the integration of non-technical aspects such as human-related practices. This paper aims to investigate the Soft Lean Practices that are necessary for the successful implementation of the Lean Production System (LPS) in the Malaysian Automotive SMEs. The result of this paper will provide a detailed review of Soft Lean ...