Lean practices implementation and their relationships with operational responsiveness and company performance: an Italian study

Although many firms report large benefits from lean implementation, a lot of scepticism still remains regarding attainable results and the possibility to apply Lean approach outside high-volume manufacturing and stable context. In this work, combining field interviews with literature review, theoretical connections have been developed among Lean manufacturing techniques, operational responsiveness and company growth performances. A conceptual model has been proposed for investigating the network of influences among lean practices (supplier management, human resource management, just-in-time and total quality management practices), operational responsiveness (Product mix variety, Product innovation and Time effectiveness) and company growth performances in Italian companies. Using structural equation modelling, a second-order confirmatory factor analysis has been used to test the hypothesised relationships in the structural models. This study highlights that the operational responsiveness is only partially connected to a Lean strategy of a company. Indeed, the lean practices implementations are negatively influenced by product mix variety and innovation, while positively influenced by time effectiveness variables. Moreover, product mix variety and time effectiveness are the main characteristics of the operational responsiveness that positively influences company growth performances. So time effectiveness could be considered as a mediator between Lean best practices and firm growth. Moreover, no direct relationship has been found between lean bundles and firm’s performances. Lack of resources and mainly poor communication and managers’ commitment and support seem to be the main obstacles of lean implementation and success.     

The impact of lean methods and tools on the operational performance of manufacturing organisations

Evidence suggests that lean methods and tools have helped manufacturing organisations to improve their operations and processes. However, the real effect of these methods and tools on contemporary measures of operational performance, i.e. cost, speed, dependability, quality and flexibility, is still unclear. This paper investigates the impact of five essential lean methods, i.e. JIT, autonomation, kaizen, total productive maintenance (TPM) and value stream mapping (VSM), on these measures. A linear regression analysis modelled the correlation and impact of these lean practices on the operational performance of 140 manufacturing organisations around the world. In addition, structural equation modelling (SME) was used to cross verify the findings of the regression and correlation analyses. The results indicate that JIT and automation have the strongest significance on operational performance while kaizen, TPM and VSM seem to have a lesser, or even negative, effect on it. This paper provides further evidence regarding the effects that lean practices have on the performance of organisations and thus the research offers companies, and their managers, a better understanding of the relationship between the lean strategy and the performance of their operations.     

Big data in lean six sigma: a review and further research directions

Manufacturing and service organisations improve their processes on a continuous basis to have better operational performance. They use lean six sigma (LSS) projects for process improvement. Therefore, this study aims to investigate the existing literature in LSS and the application of big data analytics (BDA) to have more confident and predictable decisions in each phase of LSS. Fifty-two articles have been identified after a careful and vigilant screening of closely related themes. Future research directions in the big data and LSS have been highlighted on the basis of organisational theories. Review presents an investigation framework consisting of BDA techniques applicable to each phase of LSS in all the dimensions such as volume, variety, velocity and veracity of big data. Review highlights the concerns of big data in LSS such as system design and integration, system performance, security and reliability of data, sustaining the control and conducting the experiments, distributed material and information flow. The review unveils the application of 8 modern organisational theories to big data in LSS with 21 key aspects of related theories and 19 distinct research gaps as opportunities for future research.     

Packaging and world class competitive products

The aim of the Irish food industry is to produce world class competitive products (WCCPs). Stating the obvious: Food and packaging are inseparable and thus WCCP status is a target also for packaging manufacturers in their own right and also as to how packaging assists food companies to achieve their aims.     

A fuzzy AHP-based performance evaluation model for implementing SPC in the Taiwanese LCD industry

Statistical process control (SPC) is one of the most practical and widely used tools to enhance product quality and reduce costs. However, the implementation of SPC has often resulted in unsatisfactory performance; moreover, there is no well-established standard for evaluation of the results of introducing the system. The present study addresses this problem by proposing an effective and convenient performance-evaluation model for implementing SPC. The proposed model draws on the DMAIC methodology of Six Sigma, the performance-evaluation model of Lin et al. (Lin, W.T., Liu, C.H., Hsu, I.C., and Lai, C.T., 2004. An empirical study of QS 9000 in the automobile and related industries in Taiwan. Total Quality Management, 15 (3), 335–378), and the fuzzy mathematical programming of Kaufmann and Gupta (Kaufmann, A. and Gupta, M.M., 1991. Introduction to fuzzy arithmetic: theory and application. New York: Van Nostrand Reinhold) to define the fuzzy indices and control values of importance, action, and performance in developing the proposed performance-evaluation model. The model is then applied in a case study of a Taiwanese liquid crystal display manufacturer. A questionnaire is designed to establish fuzzy indices of importance, action, and performance values for assessment by analytic hierarchy process methodology. Various critical factors and feasible improvement strategies are then compared (using computed weights) to determine the priority of the improvement strategies. To verify improvement, the same model is used to re-evaluate system control performance after implementing the improvement strategies for some time. The study demonstrates that the proposed model is an effective and convenient tool that can be used to analyse and improve the performance of an existing SPC system or to enhance success in implementing a new SPC system while working within constraints of time and costs.     

作业成本法在中国制造企业应用的案例研究

通过对某企业的具体案例分析,阐述了ABC法的局限性,包括企业本身没有完全满足ABC法使用基本前提造成的问题,以及该系统本身不可克服的缺陷。在此基础上,比较了几种改进方法的优缺点,并得到了国内生产制造企业应用ABC法的几点启示。     

Downtime variability: the impact of duration–frequency on the performance of serial production systems

It is intuitively appealing to measure downtime in terms of total time lost (i.e. frequency times duration). However, the same total downtime can be produced by an infinite number of frequency/duration combinations. This study reports the findings of a computer simulation study on the impact of varying combinations of downtime frequency/duration pairs on performance of serial production systems. The research reported here clearly shows that different downtime frequency/duration combinations affect serial production lines differently even when the total downtime remains equal. Analysis suggests that long duration, infrequently occurring variation has a much more negative impact on system performance than short duration, frequently occurring variation.     

汽车行业本地化分阶段准时供货的实例

日本丰田汽车公司首创了准时生产方式,要求供应商准时供货。1990以来,上海汽车制造行业的一批合资企业开始了对准时生产模式的尝试,并在准时供货方面取得了一定的经验。本文介绍了在我国现有的国情下,过渡期本地化的准时供货的实践,讨论了准时供货存在的问题及相应的解决对策。     

精益生产在日本的发展状况

根据在日本考察的情况,综合目前国内外对精益生产模式的研究结果,提出新的精益生产结构体系：以计算机网络支持的并行工程（CE）和小组工作式（TW）为基础,由准时化生产（JIT）、柔性自动化生产（FAP）、全面质量管理（TQM）和专业化协作生产（SCP）四根支柱支撑,精益生产则是房屋的屋顶。其中准时化生产和柔性自动化生产是精益生产的核心,以人为中心是精益生产的指导思想。文章还介绍了丰田汽车生产方式的新发展--点菜设计和大规模定制生产。     

基于活动的管理的实施步骤

基于活动的管理（ABM）是目前国际上较为先进的管理方法,其科学性和可行性得到认同,然而,如何实施仍然是亟待解决的问题,本文给出了寻找改进的机会,寻找根本的原因,寻找可行方案,执行最佳方案和监控实施的结果等实施ABM的实施步骤。     

IT in lean-based manufacturing industries: systematic literature review and research issues

This systematic literature review is the first to explore the role of IT in lean manufacturing contexts, characterising literature on the field, identifying and exploring the main issues approached, and identifying potential future lines of research. Grounded on an accurate screening process, 124 papers were selected for analysis from the SCOPUS and the ISI Web of Knowledge databases. The structured content analysis process highlights five key issues approached in literature: (1) software and technologies used, (2) benefits achieved through applying IT in lean manufacturing, (3) importance of IT integration, (4) IT and lean as complementary or independent options and (5) role of human resources. Despite an apparent scepticism concerning compatibility between IT and lean, claiming that IT may lead to processes’ complexity, extra tasks, resource consuming, among other issues, among other key findings, the review shows that several different IT instruments may boost improvements, acting as a facilitator in developing lean industrial environments, especially when lean-based improvement processes are introduced first, and then IT infrastructures. Because both IT and Lean may require significant investments in terms of managerial attention, employees’ capabilities and financial resources, it is important for management to balance investment decisions. Authors point to several shortcomings in literature which represent significant opportunities for further research: (1) significant lack of integrated comprehensive frameworks, (2) lack of knowledge concerning hybrid manufacturing systems, supply chains as research unit of analysis, how organisations can respond to staff resistance, and role of IT across the distinctive stages of lean maturity.