An integrated design methodology based on the use of group AHP-DEA approach for measuring lean tools efficiency with undesirable output

The selection of lean tools is one of the crucial factors for decision makers and practitioners in a competitive environment. A few efforts have been made based on problem selection. Conversely, numerical studies have been done on analytical hierarchy process (AHP)–data envelopment analysis (DEA) as well as DEA-undesirable variables separately. Thus, there is a shortage of lean practitioners as well as the methods involved. The present research aims at integrating AHP and DEA with desirable and undesirable factors to evaluate the lean tools and techniques and to rank the aspect of efficacy. We suggest a logical procedure to measure the efficacy of lean tools on leanness and to prioritize them as decision makers. In this extensive research, we apply the integrated multicriteria decision-making approach, including the hybrid groups AHP and DEA models with desirable and undesirable variables, to assess the relative efficiency of lean manufacturing tools and techniques. Case studies are used to demonstrate the lean implementation in companies while being validated by a panel of experts. The integration of these approaches has created synergy and shown to be even more powerful. Thus, the proposed integrated AHP-DEA model can evaluate and rank different alternatives while considering desirable and undesirable variables in the production processes.