The challenges of lean manufacturing implementation in SMEs

Green supply chain, green leadership, consumer preferences, sustainability attitudes, and sustainable business advantage: a case of Vietnamese textile industry

Surging environmental issues confiscate stakeholders' attention due to growing competition. Sustainable performance in this regard is viewed as a suitable tool because it not only gauges firm's financial performance but also covers social and environmental areas. However, sustainable performance cannot be achieved without creating sustainable business advantage. Green supply chain practices are known to be implemented in terms of sustainability as they are cross-looped as well as cross-organizational. The practices help in the reduction of environmental impact of business activities without compromising on quality, performance, cost, and energy usage efficiency. The reason encourages the authors to explore the role of selected green supply chain factors, customer preference, and leadership factors in shaping sustainable business advantage. The study has examined the association by adopting the quantitative research method. The researcher has gathered data from 530 employees in the purchasing department, logistics, import/export officers, and packing staff. The data was analyzed statistically by employing SPSS for preliminary analysis and AMOS for testing the structural model and the hypotheses of the study. Using confirmatory factors analysis and structural equational modeling, the researcher has analyzed the study's measurement model and the hypotheses of the study. The findings of the research have depicted that there is a significant positive impact of lean management and green product design with sustainable business advantage. Moreover, there exists a mediation of customer preferences and leadership factors between green product design and sustainable business advantage. The study has a few limitations as well and uses a quantitative method; therefore, the study has recommended that future researchers utilize qualitative or mixed methods. The study has several theoretical and practical implications.

Transforming product development and production to be lean for improving business performance

Purpose

In this study, the authors assess the current state of lean product development and the lean production shop floor, along with the impact of the former on process quality and the latter on product quality and customer complaint reduction. The interplay between process and product quality and customer complaint reduction is assessed, along with their impacts on business performance.

Design/methodology/approach

Data were collected from 377 managers working at auto-component manufacturing firms in India. Confirmatory factor analysis was used for scale validation, and structural equation modelling was employed to test the research hypotheses.

Findings

The results of the statistical analyses reveal the positive influence of a lean production shop floor on process quality and lean product development on product quality and customer complaint reduction, and thereby on business performance.

Practical implications

The findings of this research provide insights into the interplay between lean and quality factors and their influence on customer complaint reduction and business performance. Practitioners can use the proposed model to strategically design unique products and improve the efficiency and effectiveness of the production shop floor, which can help enhance the product and process quality. This can reduce customer dissatisfaction and improve the business performance.

Originality/value

Few studies have simultaneously investigated the influence of lean product development and lean production shop floors in the Indian manufacturing context. To the best of our knowledge, this study is one of the first attempts to include customer complaint reduction as a construct in a lean model. It helps identify and prioritise the enablers of business performance and provides valuable insights for practitioners to strengthen lean implementation to attain a competitive edge.

Lean manufacturing and firms’ financial performance: the role of strategic supplier partnership and information sharing

Purpose

The purpose of this paper is to examine the mediating role of strategic supplier partnership and moderating role of information sharing (IS), in the relationship between lean manufacturing and firms’ financial performance (FP).

Design/methodology/approach

Utilizing the contingency approach, this study develops a research model to validate the proposition that a proper integration of supply chain (SC) practices enhances the financial performance of the firm. The study uses data from one hundred and fifty-seven manufacturing firms. The results are generated on structural equation modeling (SEM) using AMOS software.

Findings

The study finds that strategic supplier partnership partially mediates the relationship between lean manufacturing and FP, whereas, empirically, it could not demonstrate that IS significantly moderates the relationship between lean manufacturing and FP.

Practical implications

The paper theoretically develops logic for and empirically shows that strategic supplier partnership is an appropriate practice for mediating the impact of lean manufacturing on FP.

Originality/value

This strategic supply chain integration contributes to theory and demonstrates that SC practices’ correct synchronization and orchestration may realize superior FP. In addition, this research provides a sustainable strategic SC model that creates value and provides a competitive advantage for firms in the long term.

The Challenges of Lean Transformation and Implementation in the Manufacturing Sector

In this study we explored the challenges involved in Lean Transformation and implementation in the manufacturing sector. Using survey data from 50 North American manufacturing organizations, we examined the challenges involved in implementing and sustaining Lean Manufacturing (LM) principles and practices in production processes. The fuzzy analytic hierarchy process (FAHP) and the fuzzy analytic network process (FANP) were used to rank the considerable challenges observed in these organizations. We concluded that the need for a change in organizational culture was the major barrier to Lean implementation. It is challenging to sustain Lean without a culture shift and a clear direction set by the organization’s leadership team. The originality of the paper relates to prioritizing the cultural aspects of organizations as a major barrier to LM implementation. Other challenges encountered during Lean implementation in the manufacturing industries were related to management support, technical knowledge, and employee resistance to change. Early identification of these challenges enables companies to question their capabilities before implementing the Lean philosophy. In this study we used results obtained from 50 manufacturing companies in North America, representing a subset of manufacturing organizations. As a result, it must be interpreted based on the data acquisition method and the study’s sample size.

Exploring the factors that hinder Lean improvement initiatives in a job shop environment: A qualitative case study of a Malaysian company

Job shop production faces various challenges regarding the use of lean manufacturing (Lean) initiatives to sustain a competitive advantage; losing the ability to maintain continual improvement of longstanding initiatives is one of the most significant. This study explores how Lean improvement initiatives can be affected by years of indifferent treatment. Consisting of a single qualitative case study conducted in a Malaysian company that has implemented Lean initiatives for more than 20 years, our findings reveal that Lean implementations in job shop environments can deteriorate over time. Our analysis identifies three overarching themes. First, even though the company has many years' experience of lean implementation, a lack of organizational engagement hindered further improvements. Second, the resource capabilities provided, became outdated, and in poor condition. Third, the company saw a rapidly diminishing level of commitment among its workers. Thus, although the company had previously enjoyed some success in implementing Lean, its ability to keep the momentum behind its initiatives began to fade. The study will help guide practitioner's actions when implementing Lean initiatives, and will enhance the knowledge of issues related to long term Lean implementations in job shop production.

Prioritization and ranking of lean practices: a case study

Purpose

The paper aims to identify, prioritize and rank lean practices in the context of an Indian automotive component manufacturing organization using interpretive ranking process (IRP) and interpretive structural modeling (ISM) approaches.

Design/methodology/approach

Lean practices are identified from the literature. Then, two hierarchical models were are developed using two distinct modeling approaches – ISM and IRP with expert opinions from an Indian automotive component manufacturing organization to analyze the contextual relationships among the various lean practices and to prioritize and rank them with respect to performance dimensions.

Findings

In the study, the hierarchical structural models are developed using ISM and IRP approaches for an Indian automotive component manufacturing organization. In ISM-based modeling, lean practices can be categorized into five levels. Top priority should be given to the motivators followed by value chain, system/technology and organization centric practices. IRP model shows the dominance relationship among the various lean practices with respect to performance dimensions.

Practical implications

The models are constructed from the organizational standpoint to evaluate their impact to the implementation of lean manufacturing. The study leverages the organizations to prioritize limited resources as per the hierarchy. Managers get the inter-linkages and ranking of various lean practices, which leads to a better perspective for the effective implementation of lean. The structural models also assist management to assign proper roles to employees/departments for effective lean implementation.

Originality/value

There is hardly any structural model of lean practices in the literature for clustering, prioritizing and ranking of lean practices. The study fills this gap and develops the hierarchical models of lean practices through IRP and ISM approaches for an Indian automotive component manufacturing organization. The results from both approaches are compared for illustrating the benefits of one over the other.

Country-related future research agenda of Lean Manufacturing–A systematic literature review

Purpose

Many future research proposals of Lean Manufacturing (LM) are presented in the literature. The purpose of this paper is to determine these future research proposals of LM which are country-related and classify them.

Design/methodology/approach

A systematic literature review (SLR) of peer-reviewed journal articles in LM was conducted. A total of 145 articles published in 34 journals during 2010–2020 were collected from four major management science publishers namely, Emerald Online, Elsevier/Science Direct, Springer Link and Taylor and Francis. The country-related future research proposals of LM identified in the literature were classified according to, firstly, the continent of the country of reference, and secondly, some form of natural affinity of these proposals creating meaningful themes. The quality tool “affinity diagram” was applied to classify the country-related future research proposals of LM.

Findings

The country-related future research proposals of LM, which are increasing in the literature over time, refer mostly to studies to be conducted in several continents/countries and to multinational studies. Conducting studies specifically in Asia, Europe, South and North America, Africa and Australia–New Zealand is also suggested. The plethora of the country-related future research proposals of LM were classified, based on the affinity of their content, into 18 meaningful themes. These themes were also classified based on their affinity into two broad categories, namely “themes concerning the LM approach itself” and “themes concerning factors outside the LM approach”.

Research limitations/implications

The restricted number of the databases searched and the subjectivity of classifying the large number of the country-related future research proposals into themes are the main limitations of the present SLR. Based on these limitations, future literature review studies can be carried out.

Practical implications

Useful proposals are provided to researchers of several countries for conducting original and country-specific research studies which can enrich the knowledge of the implementation of LM under the specific circumstances of a country for the benefit of practitioners.

Originality/value

This study goes beyond previous literature review studies on LM by focusing exclusively on the LM future research agenda which is country related. The analytical presentation of the country-related future research proposals as well as the formulation of clusters of these proposals make the present SLR study substantially different from those carried out worldwide so far.

Managing emergency situations with lean and advanced manufacturing technologies: an empirical study on the Rumbia typhoon disaster

Purpose

This study aims to examine the impact of lean manufacturing (LM) on the financial performance of companies affected by emergency situations. It additionally explores the role of advanced manufacturing technologies (AMTs) in complementing LM to enhance financial performance in emergency and non-emergency situations.

Design/methodology/approach

Both survey and archival data were collected from 219 manufacturing companies in China. With longitudinal data collected before and after an emergency situation (i.e. Typhoon Rumbia), regression analysis was conducted to investigate the effects of LM and AMTs on financial performance in different contexts.

Findings

Our results reveal an inverted U-shaped relationship between LM and financial performance in the context of emergency. We also found that AMTs exerted a positive moderation effect on the inverted U-shaped relationship, indicating high levels of AMTs that mitigated the inefficiency of LM in coping with supply chain emergencies.

Research limitations/implications

Through simultaneous investigation of LM and AMTs as bundles of practices and their fit with different contexts, this study takes a systems approach to fit that advances the application of contingency theory in the Operations Management literature to more complex patterns of fit.

Originality/value

This study illuminates how AMTs support LM practices in facilitating organizational performance in different contexts. Specifically, this study unravels the interaction mechanisms between AMTs and LM in influencing financial performance in emergency and non-emergency situations.

Supply chain performance for a traditional shipbuilding industry in Indonesia

Purpose

Study in supply chain performance research on the shipbuilding industry is lacking. The purpose of this research is to study and provide guidelines to improve the performance of traditional shipbuilding supply chains in Indonesia.

Design/methodology/approach

The paper develops an empirical study gathered from a traditional shipbuilding industry, its suppliers, and customers. This study consists of three sections: the traditional shipbuilding industry, the suppliers, and the individual supplier scores. The internal and external performances in this study are measured using Supply Chain Operations Reference (SCOR) metrics. The SCOR model identifies five performance measurement attributes, including reliability, flexibility, responsiveness, cost and assets. Instead of using “responsiveness,” this study applies the schedule performance index, and supplements “cost” with the cost performance index in order to accurately reflect the traditional shipbuilding supply chains processes.

Findings

By analyzing SCOR metrics in the traditional shipbuilding industry, it has been found that the ideal shipbuilding supply chain metrics are order fulfillment, flexibility, asset turnover and total supply chain costs. The lowest performance metric value in the traditional shipbuilding industry is the cost of goods. Some improvements are proposed to lower the high cost of ship building. An integrated economic ordering system in collaboration with all the suppliers is one of the most effective ways to reduce the cost of the traditional shipbuilding supply chains. The implementation of SCOR metrics enables management to identify the critical issues to improve.

Research limitations/implications

The study applies SCOR metrics to improve the traditional shipbuilding supply chains performance. The study is limited because the data collected are based on one shipbuilding industry only.

Originality/value

To the author's knowledge, this is the first empirical analysis on the implementation of SCOR metrics to the traditional shipbuilding industry. The analysis to improve the traditional shipbuilding supply chains performance can provide managerial insights to other industries.

Reckoning with the barriers to Lean implementation in Northern Indian SMEs using the AHP-TOPSIS approach

Purpose

The purpose of this study is to recognize critical barriers for Lean manufacturing practices implementation in small and medium enterprises (SMEs) focusing in the context of a developing economy. The advancement of SMEs is of utmost important for a surge in exports while competing with other countries and these barriers have to be given due importance as they play a major role in stalling the overall development of SMEs.

Design/methodology/approach

In this present investigation, 26 barriers to Lean implementation in SMEs have been identified after an extensive study of the literature available on the subject. After that, the influential barriers were investigated through the Analytical hierarchy process-Technique of order preference by similarity to ideal solution (AHP-TOPSIS) method using priority weightage given to them by different experts in their industries. The ranking given to the barriers is based on the AHP-TOPSIS method and has been validated by the sensitivity analysis.

Findings

The investigation reveals that for the successful implementation of Lean manufacturing practices, the will of the management, individual will power and contribution of the people matter a lot apart from other barriers such as flexibility, expertise of the people, resources and resistance offered by the people to new programs. The solutions for overcoming these barriers are also provided in this study and a model has been suggested for the same.

Research limitations/implications

This work was devoted to the evaluation of obstacles in the introduction of Lean practices and prioritizing them. But it was limited to the medium- and small-scale organizations located in Northern India. Further studies can expand the scope to the large-scale units in the field. Moreover, the scope of this study was confined to the manufacturing sector. Future studies can extend it to the non-manufacturing environments such as the service sector, health care, etc. This investigation was based on the judgments of industry experts and academicians. Another approach such as Viekriterijumsko kompromisno rangiranje can be used for future investigations.

Originality/value

This study is significant when keeping in mind the contribution of SMEs to a country’s economy, especially in the Indian context.

Analysis of lean implementation barriers in Indian ceramic industries: modeling through an interpretive ranking process

Purpose

The purpose of this paper is to identify and prioritize the lean implementation (LI) barriers in the context of labor intensive Indian ceramic industries through a statistically reliable and validated model.

Design/methodology/approach

In this study, LI barriers are identified through a comprehensive review of relevant literature and discussions held with academicians/practitioners. Identified barriers, thereafter, are evaluated with Cronbach's alpha values using a statistical tool. The interpretive ranking process (IRP) methodology is applied for ranking of the barriers with reference to the measurable performance indicators.

Findings

The study identified highly relevant barriers of Indian ceramic industries. Further, these barriers were compared with performance measures through a cross-interaction matrix developed in the IRP model. The model highlights the analysis of dominance relationship of different barriers. Moreover, the result shows that top management commitment and leadership is at the top of the model, followed by lack of training opportunity and skills, and resistance to change and adopt innovations indicating their strongest driving power in LI.

Practical implications

This model may enable the firms to understand the LI barriers and come up with sensible implementation program. Further, the correlation results among the barriers will provide insights in mitigating the hurdles of lean manufacturing (LM) implementation in the industries.

Originality/value

This study empirically develops a model through the IRP for the barriers in LM implementation. From the reported literature, it appears that the application of IRP is very rare in ceramic industries in India. The analysis and prioritization of LI barriers may help practitioners to plan strategies to implement lean in a selected domain.

An SEM Approach for the Barrier Analysis in Lean Implementation in Manufacturing Industries

This paper investigates the barriers that hinder the implementation of lean manufacturing in wood and furniture industries as the adoption of this philosophy in such industries is not promising especially in emerging economies. To this end, a comprehensive review of the literature was performed to identify the barriers and develop a conceptual model. Next, structural equation modeling is employed to examine the model using the collected data from 131 wood and furniture companies. The findings revealed a synergetic effect between three key factors—culture and human attitude, knowledge, and resources—which play a crucial role in implementing lean. The analyses indicated the reasons of companies refused or not ready to implement lean on knowledge and culture and human attitudinal issues, particularly in companies that have limited resources. It is believed that resource issues are an obstacle to lean implementation, but not as important as knowledge and culture and human attitudinal issues. Sufficient knowledge is needed to deploy lean practices as well as changes in culture and human attitude. Investigating the relationships between these three key barriers is a contribution that this study intends to become a forward step for promoting lean manufacturing among under-studied industries. This paper also proposes that through adopting the activities for lean implementation, small and medium enterprises can experience and quantify the positive impacts of lean practices. Government agencies, universities, and professional bodies can support such enterprises in this transition through targeted interventions that address the barriers presented.

Analyzing the Lean Six Sigma enabled organizational performance to enhance operational efficiency

Purpose

The aim of this analysis is to review the Indian manufacturing organizations practicing Lean Six Sigma (LSS) tools/techniques with an objective of monitoring the performance of an organization and to develop recommendation for strategies to benchmark organizational operational efficiency.

Design/methodology/approach

This study offers insights of the LSS performance measurement aspects of the Indian manufacturing organizations based on Data envelopment analysis (DEA) approach. The five inputs and two outputs are considered on the basis of literature review and discussed with the practitioners.

Findings

In this analysis, the relative efficiency score of 18 Indian manufacturing organizations has been determined in order to assist evaluation of the impact of monetary investment on the outputs. The present analysis not only investigates the optimum level of input variables but also lays down a significant observation that an organization having higher profit and inventory turnover ratio is not necessarily an efficient organization.

Practical implications

The results assist to determine the best practice units, potential source of inefficiency and deliver beneficial data for the consistent enhancement of the operational efficiency. The DEA results assist managers and decision makers to derive appropriate strategies to enhance their performance with reference to the efficient organization and to regard it as their role model.

Originality/value

This analysis renders a DEA based framework of LSS practicing Indian manufacturing organizations. The framework is unique in terms of its input-outputs variable selection and measurement procedure.

Continuous improvement framework to develop cultural change: case study, capital goods company

Purpose

In this study, a frame of reference was developed to adapt and execute a continuous improvement process (CIP) for reinforcing a continuous improvement (CI) culture in an organisation. The study was undertaken in a mature capital goods company that did not succeed in institutionalising CI despite deploying many CI tools over the years. The organisation thus needed a model that was adapted to its reality and strengthened the aspects of CI through cultural changes at the organisational level.

Design/methodology/approach

Action research was used to implement the CIP, and this research method was reinforced using a hermeneutic phenomenological approach to analyse the results.

Findings

The CIP was validated in four units of analysis within the organisation. For the validation, aspects relevant to organisational cultural change and their metrics were identified. The results showed that the main barriers to the development of CI in the case organisation were lack of teamwork and poor assimilation of new CI routines.

Research limitations/implications

The study was applied only in one organisation. Therefore, results cannot be generalized although the process and methodology followed to adapt and implement the CIP could be applied within other organisations.

Originality/value

The paper presents a CI frame of reference and describes how a CIP applied to a small- and medium-sized industrial enterprise generated cultural changes and promoted organisational excellence in the pursuit of CI, by using a hermeneutic phenomenological methodology approach.

Assessing the Sustainment of a Lean Implementation Using System Dynamics Modeling

The adoption of the lean approach has yet to extend to the majority of manufacturers in developing countries where traditional work practices are dominant and cultural resistance to change is high. This research consists of a case study about lean implementation at a clothing manufacturer in a developing country. Production wastes are identified and appropriate lean techniques, namely Total Productive Maintenance, Kanban and Supermarket Pull, are identified to eliminate or reduce them. The potential impacts on the manufacturing system are first assessed using a system dynamics model. The modeling results showed a “getting worse before getting better” behavior as work-in-process increased in the short-term, before a net reduction of 34% on average was achieved over the first 3 months. This result was replicated by a similar trend in the actual lean implementation on the factory floor, showing the usefulness of SD modeling for supporting the sustainability of lean interventions where short-term drawbacks can be deceptive when compared to the long-term benefits of lean.

An integrated approach for prioritizing lean and agile production factors based on costs of quality with a case study in the home appliance industry

Purpose

The purpose of this paper is to prioritize lean production (LP) and agile production (AP) factors based on costs of quality (COQ).

Design/methodology/approach

After literature review, two separated houses of quality (HoQ) have been developed. By the first HoQ, LP and AP factors can be proritized based on prevention and appraisal costs and by the second HoQ, LP and AP factors can be prioritized based on failure costs. The proposed approach has been examined by analyzing data collected from 36 home appliance producers of Isfahan as an industrial province of Iran.

Findings

The first HoQ indicates that the highest and the lowest priorities are related to over-production (lean factor) and speed (agility factor), respectively. The second HoQ implies that the highest and the lowest priorities are related to responsiveness (agility factor) and inventory (lean factor), respectively. Quadrant analysis also indicates that defectives and over-processing are the two factors that have the highest priorities based on both failure costs and appraisal and prevention costs. As a major finding, LP factors have strong relationship with prevention and appraisal costs; and AP factors have strong relationship with failure costs.

Practical implications

The proposed approach helps organizations in reducing their costs. By clarifying the relationship of the LP and AP factors and the COQ, managers can determine appropriate strategies with the lowest cost.

Originality/value

The integrated approach of this study has not been applied and studied in the literature. The subject of the relationship of LP and AP and COQ is relatively new, which integrates the two areas of production management and quality management.

Assessing Lean adoption in food SMEs: Evidence from Greece

Purpose

The purpose of this paper is to determine the current state of the Lean principles adopted by food small and medium-sized enterprises (SMEs).

Design/methodology/approach

The case study approach was undertaken in order to gain insights into Lean adoption. Nine Greek food SMEs certified according to the ISO 9001 quality management system (QMS) and the ISO 22000 food safety management system (FSMS) were approached. Interviews were conducted with the chief executive officers and the company managers in charge of the QMS or FSMS, based on a structured questionnaire.

Findings

The food SMEs participating in the present study adopt Lean principles to a high extent. However, there is room for further improvement.

Research limitations/implications

The fact that the data collected suggests subjective business evidence and not objective as well as the fact that only two representatives of each of the nine food SMEs were conducted, comprise the main limitations of the present study. So, the results should be considered with caution, as far as the Lean adoption in the Greek food sector is concerned. Based on these limitations, future research suggestions can be made.

Practical implications

Based on the present study, suggestions can be made regarding the successful adoption of Lean principles, not only for the sample SMEs but also for the whole of the food sector. More specifically, by determining the strengths and weaknesses of the food SMEs’ efforts to adopt Lean, suitable managerial initiatives can be undertaken by these companies as well as the whole sector to fully adopt Lean and derive the respective benefits.

Originality/value

The paper provides insights into the adoption of Lean principles in the Greek food sector. This is the first study in the field of Lean that has been carried out in the Greek food SMEs.

Strategies for modern operations management

Purpose

This research enlarges the debate on the operations management strategies pursued by manufacturing companies. The purpose of this paper is to focus on issues concerning servitisation and customisation, enterprise resource planning (ERP) and Lean-agile, supply chain orchestration, corporate social responsibility (CSR) and Lean for design management.

Design/methodology/approach

A questionnaire of eight questions which stemmed from a literature review was completed by 152 senior operations managers from 120 large European manufacturing companies. Responses were scaled from strongly agree to strongly disagree. The results were tested for reliability using Cronbach’s α test. The questions were tested through a one-sample t-test.

Findings

The 152 respondents consider servitisation and standardisation to be a trade-off. They consider integration of ERP strategies with Lean and agile systems and customised products/processes to be difficult. Furthermore, suppliers’ orchestration is considered not that suitable for manufacturing companies and suppliers’ CSR performance measurement excessive. By contrast, a CSR internal performance measurement is helpful for increasing sales. The respondents also indicate that there is a lack of Lean tools for design and development processes and Six Sigma is the only strategy for improving quality performance in design and development processes.

Research limitations/implications

The findings are applicable only to the manufacturing sector. The findings of this research indicate many avenues of research for scholars.

Practical implications

The findings can be very useful for manufacturing operations managers deciding their future strategies on operations.

Originality/value

Findings related to servitisation and customisation, ERP and Lean-agile, supply orchestration for manufacturing companies and Lean and agile for product design are original and open a valuable debate.

The emergence and evolution of benchmarking: a management fashion perspective

Purpose

The purpose of this paper is to make a contribution to the benchmarking literature by examining the historical emergence and evolution of benchmarking using the management fashion perspective as a theoretical lens.

Design/methodology/approach

The research approach followed in this paper can be characterized as explorative and theoretical. Insights from different data sources have been combined to provide a rich description of the emergence and evolution of benchmarking.

Findings

This analysis casts new light on several aspects of benchmarking’s emergence and evolution pattern. The characteristics of the benchmarking idea give it potential as a fashionable management tool. The widespread popularity and longevity of benchmarking can to a large extent be explained by the efforts of various actors to turn benchmarking into an institution.

Research limitations/implications

The paper is explorative and is limited by a reliance on secondary sources.

Originality/value

Although some researchers have noted that benchmarking could be viewed as a management fashion, management fashion theory has, only to a very limited extent, been used as a theoretical lens in the context of benchmarking. This research paper demonstrates that management fashion theory can provide valuable insights for research on benchmarking.

The impact of Lean bundles on hospital performance: does size matter?

Purpose

The purpose of this paper is to study the effect of the implementation of Lean bundles on hospital performance in private hospitals in Jordan and evaluate how much the size of organization can affect the relationship between Lean bundles implementation and hospital performance.

Design/methodology/approach

The research is considered as quantitative method (descriptive and hypothesis testing). Three statistical techniques were adopted to analyse the data. Structural equation modeling techniques and multi-group analysis were used to examine the research’s hypothesis, and to perform the required statistical analysis of the data from the survey. Reliability analysis and confirmatory factor analysis were used to test the construct validity, reliability and measurement loadings that were performed.

Findings

Lean bundles have been identified as an effective approach that can dramatically improve the organizational performance of private hospitals in Jordan. Main Lean bundles – just in time, human resource management, and total quality management are applicable to large, small and medium hospitals without significant differences in advantages that depend on size.

Originality/value

According to the researchers’ best knowledge, this is the first research that studies the impact of Lean bundles implementation in healthcare sector in Jordan. This research also makes a significant contribution for decision makers in healthcare to increase their awareness of Lean bundles.

Lean and US manufacturing industry: popularity of practices and implementation barriers

Purpose

The purpose of this paper is to analyze lean strategic practices being implemented in manufacturing facilities throughout Pennsylvania and West Virginia and identify the difficulty in implementing those lean practices.

Design/methodology/approach

A skip logic questionnaire was developed into multiple sections for analysis; demographics of respondents, identification of the knowledge and practice of lean methods, interpretation of lean application, strategic direction of lean methods, measurements of expertise, and difficulties for practicing lean. The questionnaire was sent to 327 manufacturing facilities where 51 usable responses were collected for the study.

Findings

Lean manufacturing is a widely recognized and practiced business philosophy as a significant percentage of manufacturers have implemented some variation of practice. However, the extent of knowledge does not mirror awareness. The application of lean manufacturing practices is not readily appropriate for every company, but adopting the concept of customer-focussed waste reduction to maximize value can be universally applied as waste reduction was the most prominent practice pursued. Lean practitioners found that poka-yoke and installing new process equipment have the highest degree of benefits from implementation while 5S and eliminating waste were the least difficult practices to implement. In general, the management personnel of the companies have an influential effect on lean manufacturing pursuance. This is illustrated by the fact of high agreement between facilities that resistance to change from employees is the most prominent difficulty for implementation followed by limited technical knowledge of lean manufacturing at operational and conceptual levels.

Research limitations/implications

The research findings are from a subset of manufacturing companies in Pennsylvania and West Virginia and may not represent all of the companies on a national level. The results must be interpreted in the context of the data acquisition approach due to the extent of the sample size involved, the procedure for how data were collected, and assuming that each lean strategic practice has the same weight to calculate the facility lean index.

Practical implications

The results provide insight about the effect of facility size and years of lean practicing for various lean strategic practices. The most beneficial and least difficult lean strategies, their implementation level, and the real challenges for implementing lean were also identified to help both lean practitioner and non-practitioner for the lean journey.

Originality/value

The research investigates current lean strategic practices pursued by manufacturers throughout Pennsylvania and West Virginia and identifies obstacles to implementation of lean practices. Lean manufacturing is widely sought after as a continuous improvement program, but success is divided. This study characterizes lean manufacturing comprehension while identifying knowledge areas of strengths and deficiencies. There lacks an established structure for lean practices to pursue. Therefore, this study provides manufacturers a measure for comparing their position for refined decision making.