Lean practices and their effect on performance: a literature review

This paper introduces a literature review of 83 studies dealing with the degree of adoption of lean manufacturing practices around the world, and the links between those practices and organisation performance. The results of this study revealed that lean practices application still occurs in a fragmented way, disregarding the systemic linkage that is essential to lean manufacturing. Forty-one articles have suggested a positive effect of lean practices in at least one operational, financial and/or environmental performance metric. Nevertheless, five studies indicated that some lean practices had a negative effect on operational or financial performance. High demand variability, a perceived result of long-term lean manufacturing implementation, a country/company’s organisational culture and the difficulty of traditional costing production systems to measure and compare investments and economic gains from adopting lean manufacturing over time are some of the reasons to explain that negative effect of lean practice on performance.     

Benefits of adopting lean production on green performance of SMEs: a case study

Abstract

Small- and medium-sized enterprises (SMEs) are widely recommended to strive, not only for their performance in operational side, but they need to integrate the environmental dimension. To do that, the literature widely indicates a positive impact of lean practices on green performance. However, very few studies have been carried out in SMEs context. In this view, this paper aims at providing through a practical case study of lean implementation in a real-life small manufacturing company, the information to confirm this synergy between lean and green performance. To achieve this aim, a proposed framework of lean and green integration has been implemented in a SME producing different types of pumps. The results achieved shows that there is a strong correlation between operational metrics improvement and green metrics improvement. Moreover, the benefits of lean practices such as 5S, Kanban, SMED, AM, cellular manufacturing and quality control on green performance are widely demonstrated. Future work could study other processes and explore other case-specific supporting tools and techniques.     

Performance Metric Portfolios: A Framework and Empirical Analysis

The widespread adoption of supply chain management principles suggests that managers recognize the importance of evaluating operational decisions holistically. However, it is often difficult to link specific operational practices to strategic level outcomes and in turn to corporate financial results. This presents problems for both managers and academic researchers attempting to justify the often high cost of operational improvement initiatives in terms of objective accounting metrics. This study provides evidence that it is possible to demonstrate linkages between carefully chosen portfolios of tactical, strategic, and financial metrics. Survey data from 118 manufacturers are used to evaluate hypotheses linking multilevel metrics of performance across three well‐established strategic foci. We present portfolios of metrics drawn from the literature and from the Supply Chain Counciľs supply‐chain operations reference model and related design and customer chain models. Our analysis suggests that metric portfolios in which tactical metrics are designed to match strategic‐level metrics, based on alignment with a specific strategic focus, provide clearer mechanisms for understanding performance linkages.     

Measuring Dynamic Capabilities: Practices and Performance in Semiconductor Manufacturing

Research on dynamic capabilities emphasizes the importance and role of organizational routines in explaining interfirm differences in performance. While performance differences are well documented, few empirical analyses explore the processes inside organizations that lead to dynamic capabilities or attempt to define and measure their performance effects. This paper examines one type of dynamic capability – the development and introduction of new process technologies in semiconductor manufacturing. This dynamic capability is an important source of competitiveness in the semiconductor industry, given the short product lifecycles, rapid price declines, and rapid technological advances that define the industry. Because much of the knowledge that underpins semiconductor manufacturing is idiosyncratic, firm-level R&D organization and information technology practices that facilitate problem solving and learning-based improvement provide important and enduring advantages. We derive models of the rate of improvement in manufacturing yield (i.e. the quality of production) and cycle time (i.e. the speed of production) following the development and introduction of new process technologies in manufacturing facilities, and test the empirical specifications of these models. The ways in which semiconductor manufacturers accumulate experience and articulate and codify knowledge within the manufacturing environment build new process development and introduction dynamic capabilities that improve performance.     

Flexible manufacturing systems performance in U.S. automotive manufacturing plants: a case study

Flexible manufacturing systems (FMS) philosophy is a key weapon in achieving global manufacturing competitiveness. It encompasses a wide range of dimensions to improve all aspects of operational performance metrics. The aim of the study is to examine the current state of flexibility adoption in U.S. automotive manufacturing facilities and its impact on operational performance metrics. It utilizes survey questionnaire developed based on previous work in U.S. manufacturing industry. The survey was originally distributed to 420 facility managers in the U.S. domestic automotive industry. It was revealed that 70% of the respondents had implemented all 15 flexibility dimensions listed in the questionnaire. The data analysis conducted shows that implementation of certain flexibility dimensions will lead to significant improvement in specific operational performance metrics. This considerable finding can be used as a guide for manufacturing managers to achieve certain objectives in operational performance improvement in a rapidly changing environment.     

The Role of Culture as Driver of Quality Management and Performance: Infrastructure Versus Core Quality Practices*

Increasingly, scholars and practitioners recognize the importance of understanding organizational culture when implementing operations management practices. This study investigates the relationships among organizational culture, infrastructure and core quality management practices, and manufacturing performance using two alternative models. Understanding these relationships is important because culture can provide insight into the context dependence of quality management practices and shed light on the mixed results of past studies concerning the link between quality management and performance. Analysis of manufacturing plants from six countries indicates that organizational culture has a stronger influence on infrastructure quality management practices than on core quality management practices, regardless of whether the plants are located in Eastern or Western countries. In addition, infrastructure quality management practices have a significant effect on manufacturing performance. These results contribute to the quality management literature by emphasizing the importance of accounting for culture when making decisions to implement quality management practices to achieve a performance advantage. Finally, we also contribute to the literature on the culture–performance linkage by finding support for a direct link between culture and manufacturing performance.     

Manufacturing Practices and Strategy Integration: Effects on Cost Efficiency,Flexibility, and Market‐Based Performance

Manufacturing plant managers have sought performance improvements through implementing best practices discussed in World Class Manufacturing literature. However, our collective understanding of linkages between practices and performance remains incomplete. This study seeks a more complete theory, advancing the idea that strategy integration and enhanced manufacturing capabilities such as cost efficiency and flexibility serve as intermediaries by which practices affect performance. Hypotheses related to this thesis are tested using data from 57 North American manufacturing plants that are past winners and finalists in Industry Week's“America's Best” competition ( Drickhamer, 2001 ). The results suggest that strategy integration plays a strong, central role in the creation of manufacturing cost efficiency and new product flexibility capabilities. Furthermore, strategy integration moderates the influences of product‐process development, supplier relationship management, workforce development, just‐in‐time flow, and process quality management practices on certain manufacturing capabilities. In turn, manufacturing cost efficiency and new product flexibility capabilities mediate the influence of strategy integration on market‐based performance. These findings have implications for practice and for future research.     

Task Design,Team Context,and Psychological Safety: An Empirical Analysis of R&D Projects in High Technology Organizations

High technology organizations need to develop new products or processes that address the dual goals of exploration and exploitation. The competing viewpoints and the asymmetric nature of market returns associated with these goals in R&D projects can heighten stress levels among project team members and reduce their psychological safety. While current research calls for greater focus on task design for improving psychological safety, we know little about how team contextual factors affect this relationship. This study develops and tests a conceptual framework that examines the moderating role of R&D team contextual factors, namely, relative exploration and project‐organization metric alignment on the relationship between a key task design variable, namely, team autonomy, and psychological safety. Relative exploration captures the extent to which exploration goals are emphasized over exploitation goals in an R&D project, while project‐organization metric alignment measures the extent to which project metrics are aligned with broader organizational metrics. Furthermore, we examine the performance consequences of psychological safety in R&D projects. The empirical analysis is conducted using primary data collected from multiple informants across 110 R&D projects in 34 high technology business units. Our results indicate that relative exploration and project‐organization metric alignment have contrasting moderating effects. Furthermore, the effect of psychological safety on project performance is found to be indirect and mediated through team turnover. Implications of the study findings, limitations, and directions for future research are discussed.     

浅谈可追溯性管理实现方案的选择

可追溯性对于当今日趋复杂的行业供应链管理，企业的资产及质量管理的贡献正不断的提升。并且随着技术的革新，可追溯性在不同行业中的实践和应用也有所不同。本文以高端半导体产品封装测试为安全的对如何进行可追溯性管理实现方案的选择进行了简要的分析。     

The Impact of Organizational Culture on Time‐Based Manufacturing and Performance

Firms are utilizing an array of manufacturing practices in their quest for survival and success in the marketplace. The implementation of those practices has not always resulted in success stories as the focus had been mostly on technical issues, with little concern for “soft issues.” For example, the enabling role of organizational culture has often been ignored. Using Schein's conceptualization of culture as underlying assumptions, espoused values, and artifacts, we examine a framework that relates culture and manufacturing practices to performance. The underlying assumption of customer orientation is posited to affect espoused values such as beliefs on investing in facilities and equipment to leverage intellectual work and to promote creativity, beliefs on working with others, beliefs on making decisions that are global, beliefs on management control, and beliefs on integrating with suppliers. The espoused values are hypothesized to affect visible attributes of culture (behaviors) such as time‐based manufacturing practices, which firms are employing for competitive advantage. A sample of 224 firms is used for developing research instruments and testing the hypothesized relationships advanced. Results indicate that high levels of customer orientation lead to a set of managerial beliefs that are collaborative and integrative. In turn, certain espoused values support a high level of time‐based manufacturing practice, which leads to high performance.     

The impact of lean practices on operational performance – an empirical investigation of Indian process industries

In deciding to adopt lean manufacturing, it is imperative to investigate where and how lean practices are most needed to influence manufacturing and business performance. Such an investigation becomes indispensable when lean thinking is to be considered in a production arrangement different to the conventional, repetitive, high-volume, stable-demand and discrete-manufacturing environment. This study provides explanations of how performance is improved through the adoption of lean practices in process industries. This is a relatively under-researched area compared to the performance effects associated with the introduction and implementation of lean principles in traditional, discrete manufacturing. Based on a survey of Indian process industries, this study attempts to develop an empirical relationship between lean practices and performance improvement through the use of multivariate statistical analysis. The findings have led to the conclusion that lean practices are positively associated with timely deliveries, productivity, first-pass yield, elimination of waste, reduction in inventory, reduction in costs, reduction in defects and improved demand management. However, within a process-industry context, lean practices related to pull production were found to have a marginal impact on performance improvement. A detailed discussion of the findings along with their theoretical and managerial implications is provided in the paper.     

Selecting human health metrics for environmental decision-support tools.

Environmental decision‐support tools often predict a multitude of different human health effects due to environmental stressors. The accounting and aggregating of these morbidity and mortality outcomes is key to support decision making and can be accomplished by different methods that we call human health metrics. This article attempts to answer two questions: Does it matter which metric is chosen? and What are the relevant characteristics of these metrics in environmental applications? Three metrics (quality adjusted life years (QALYs), disability adjusted life years (DALYs), and willingness to pay (WTP)) have been applied to the same diverse set of health effects due to environmental impacts. In this example, the choice of metric mattered for the ranking of these environmental impacts and it was found for this example that WTP was dominated by mortality outcomes. Further, QALYs and DALYs are sensitive to mild illnesses that affect large numbers of people and the severity of these mild illnesses are difficult to assess. Eight guiding questions are provided in order to help select human health metrics for environmental decision‐support tools. Since health metrics tend to follow the paradigm of utility maximization, these metrics may be supplemented with a semi‐quantitative discussion of distributional and ethical aspects. Finally, the magnitude of age‐dependent disutility due to mortality for both monetary and nonmonetary metrics may bear the largest practical relevance for future research.     

Developing an understanding of lean thinking in process industries

The research described in this article has set out to determine the extent to which lean thinking is being adopted as a manufacturing philosophy by process industries. It concerns the application and examination of key lean manufacturing principles, namely, the alignment of production with demand, the elimination of waste, the integration of suppliers (IS) and the creative involvement of the workforce in improvement activities, to a range of process industry types based on Dennis and Meredith's taxonomy of process industry transformation systems [Dennis, D. and Meredith, J., 2000a. An empirical analysis of process industry transformation systems. Management Science, 46 (8), 1085–1099]. Seventy-nine process industry product streams across 62 sites were studied. In addition, a five-site investigative field study was also undertaken. The findings demonstrate that lean practices associated with the elimination of waste are consistently used for improving manufacturing performance throughout the taxonomy of process industries but practices associated with other lean principles are inconsistently applied. In addition, explanations are provided on the appropriateness of lean thinking as a manufacturing philosophy and a strategy for improving manufacturing performance in different process industry types, and on the extent to which lean principles and practices are dependent on the characteristics of process industry transformation systems.     

LEAN,GREEN, AND THE QUEST FOR SUPERIOR ENVIRONMENTAL PERFORMANCE

We examine the relationship between lean manufacturing practices and environmental performance as measured in terms of air emissions and resource use. We draw on two unique surveys of 31 automobile assembly plants in North America and Japan, which contain information on manufacturing practice and environmental performance, as well as in‐depth interviews with 156 plant level employees at 17 assembly plants. Our survey results and interviews suggest that lean management and reduction of air emissions of volatile organic compounds (vocs) are associated negatively. Lean manufacturing practices contribute to more efficient use of paints and cleaning solvents, but these in‐process changes are not sufficient to meet the most stringent air regulations. We found some evidence to support the link between lean practices and resource efficiency. While our survey results were in hypothesized direction, they were not statistically significant. In‐depth semi‐structured interviews, however, suggest a more robust relationship, and we use them to describe some mechanisms by which all three aspects of lean management (buffer minimization, work systems, and human resource management) may be related to environmental management practices and performance.     

Innovation by Operating Practices in Project Alliances – When Size Matters

Project alliances offer firms an opportunity to increase innovation performance through the flexible combination of specialized competencies across firms. Inspired by internal project management I classify two metrics of project alliances: formal and emergent operating practices. This study of 166 project alliances analyses the innovation performance impact of those practices. I find that emergent operating practices improve planned and serendipitous innovation regardless of a firm's size. After a classification of two groups, small and large firms, I find that firm size moderates the effect of formal operating practices. Results show that small firms can improve their innovation performance by formal operating practices. Instead, large firms will face performance reductions on planned innovation when implementing formal operating practices.     

Green logistics management and performance: Some empirical evidence from Chinese manufacturing exporters

The value chain of many business enterprises is increasingly required to demonstrate the profitability of their primary activities, starting from inbound logistics to operations, outbound logistics, marketing sales, and finally to services. The adoption of green logistics management (GLM) presents an opportunity for Chinese manufacturing exporters to competently respond to the escalating expectation of the international community for resources conservation and to achieve environmental performance profitably. This study makes several important contributions to the literature on managing logistics with environmental considerations. First, the authors identify the components of GLM: (i) procedure-based practices, (ii) evaluation-based practices, (iii) partner-based practices, and (iv) general environmental management practices. Second, they relate GLM to environmental and operational performance in a developing country context. Third, they identify the institutional and operational antecedents that prompt the adoption of GLM by export-oriented manufacturing enterprises in China. Fourth, they examine the moderating effect of environmental regulatory pressure on the GLM-performance linkage. The results are based on a survey of manufacturing exporters in China. The commonly held view that economic motivation is related to the adoption of GLM is not supported. However, GLM positively affects both environmental and operational performance, and regulatory pressure enhances the GLM-performance relationship.     

Assessment of systemic greenness: a case study of tyre manufacturing unit

Abstract

In this paper, we develop an assessment framework to evaluate the systemic greenness of a tyre manufacturing unit by capturing the interactions between the green practices implemented. By reviewing the existing literature, we propose a stakeholder-based green practices framework comprising of operation strategy practices, process practices, employee practices, regulatory practices, customer practices, competition practices, social practices, and supplier practices. The empirical data on the interactions of green practices between and within stakeholders are collected by conducting a detailed case study of a large radial tyre manufacturing unit in India. We use graph-theoretic approach to incorporate the interactions between different green practices and assess the systemic greenness of the case organisation. Based on the systemic greenness attained, we rank the green practices within stakeholders and also between the stakeholders. We conduct scenario analysis to develop a systemic greenness index and a scale to assist practitioners in evaluating and benchmarking the greenness performance. We also discuss implications for theory and practice along with the inherent limitations.     

Dynamic Benchmarks for Operations Evaluation Using Soft Computing Methods*

New dynamic benchmarks are developed as performance metrics for operational activities in the ingot mill of an aluminium smelter. This new type of high-level performance measure enables both a systematic and a holistic appraisal of operations performance that is not possible at present. The benchmarks also allow changes in performance of each distinct resource group to be clearly identified. The method for computing such measures is based on a wide range of shop-floor data, and possibility theory is used to model the soft characteristics of much of the input. Fuzzy performance estimates are dynamically updated with special attention to combining the different forms of uncertainty that exist in the input information. Although these procedures are site specific, the methodology is applicable to other types of manufacturing systems.     

Implementing lean sigma in an Indian rotary switches manufacturing organisation

The manufacturing organisations have been witnessing a transformation in the manufacturing paradigm. Lean sigma and six sigma are the two business process improvement strategies widely employed by organisations to enhance their manufacturing performance. To achieve dramatic result in cost, quality and time, best strategies need to be applied to enhance the process performance. Lean sigma and six sigma are two powerful and effective strategies, enabling the organisation to overcome their weakness and for retaining their improvement. Lean sigma combines the variability reduction tools and techniques drawn from six sigma with the waste and non-value added elimination tools and techniques from lean manufacturing to achieve savings in the organisations. This study uses an integrated lean sigma framework to reduce the defects occurring in the final product, thereby contributing savings to the organisation. The proposed framework integrates lean tools within six sigma methodology to enhance the bottom-line results and to win customer loyalty. The implementation of the proposed framework shows dramatic improvement in key metrics and substantial financial savings to be generated by the organisation.     

An Integrated Framework for Measuring Product Development Performance in High Technology Industries

We present an integrated framework for measuring product development performance. The framework consists of a three stage model for exploring the relationships between metrics used by design, manufacturing, marketing functions, and overall commercial success. Using a cross‐sectional survey of 383 product development professionals working on 38 product development projects in the high‐tech electronic assembled goods manufacturing sector, we provide empirical evidence of the proposed framework. The findings indicate that in the high‐tech manufacturing sector (1) commercial success of new product development projects is primarily determined by market share, (2) gain in market share is primarily driven by lower unit cost and not by technical performance, and (3) reduction in unit cost is primarily driven by the increased speed of new product development and not by the R&D budget. The study failed to identify any significant association between R&D budget and technical performance, and development speed and technical performance.