Could “Lean Lite” be the cost effective solution to applying lean manufacturing in developing economies?

Does organizational readiness matter in lean thinking practices? An agency perspective

Purpose

Extant research documents the importance of lean thinking for organizations, however, as prior research has largely focused on hard lean practices, but little is known about the effects or the significance of soft lean practices. This research attempts to address this issue by examining how soft lean practices enhance organizational lean readiness, and in turn increase the success of lean implementation.

Design/methodology/approach

This research adopts a single case study design in a small-medium enterprise livestock feed manufacturing organization, and investigates the period from late 2011 through the end of 2019 covering two attempts at lean implementation – an initial failed attempt followed by a successful introduction of lean within the case organization. The research analyzes interviews with 29 managers and employees from all organizational levels and departments within the case organization. Secondary data including organizational documents and performance measures and metrics were also incorporated into the research design.

Findings

Drawing on agency theory, the authors advance a principal-agent interaction perspective to conceptualize organizational lean readiness – specifically, the authors consider the “state or condition” of four agency factors (goal conflict, information asymmetry, risk aversion and length of relationship), and explore if these four agency factors can be utilized as proxies for organizational readiness for lean implementation. The authors identify the formation of a shared vision and identity within the organization as an effective mechanism through which soft lean practices enhance organizational lean readiness. Finally, the analysis offers an understanding of how the long-term success of lean implementation is improved by the introduction of soft lean practices as a prerequisite to create organizational readiness for the implementation of hard lean practices.

Originality/value

The study is unique in the sense that it empirically links agency theory and the role of soft lean practices in developing organizational lean readiness in a small-medium enterprise context by defining the ideal state of four agency factors as proxies for organizational readiness.

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.

SME productivity stakeholders: getting in the right orbit

Purpose

The purpose of this paper is to explore who small and medium-sized enterprise (SME) owner–managers consider as key stakeholders for their business for helping increase productivity and the nature of the stakeholders' impact.

Design/methodology/approach

The study uses the Lego Serious Play methodology and narrative analysis in a focus group setting.

Findings

The analysis revealed a narrow depth of field of productivity stakeholders and identified critical narratives, involving close stakeholders which could constrain productivity. Lack of information on current and/or future productivity states, and a social brake due to the potential impact on employees are two at the forefront of owner–manager perspectives. The study also identified the importance of internal and external champions to improve productivity and re-enforced the significance of skills gaps, the role of Further Education providers and other infrastructure assets.

Research limitations/implications

The purposiveness sample of the single focus group setting results in a lack of generalizability, but provides potential for replication and transposability based on the generic type of stakeholders discussed. The work highlights the potential to further enhance the constituent attributes of stakeholder salience.

Practical implications

There is a potential for different network agents to increase their collaboration to create a more coherent narrative for individual productivity investment opportunities and for policy makers to consider how to leverage this.

Social implications

The findings suggest that the implications of deskilling and job loss are major factors to be considered in the policy discourse. SMEs are less likely to pursue productivity improvements in a low growth setting because of their local social implications.

Originality/value

The study is innovative in using Lego to elucidate narratives in relation to both stakeholder identification and their contributions to productivity improvement impact in a UK SME context. The study introduces an innovative stakeholder orbital map and further develops the stakeholder salience concept; both useful for the future conceptual and empirical work.

Research gaps in Lean manufacturing: a systematic literature review

Purpose

Literature contributions to Lean manufacturing (LM) are fragmented and show some significant limitations. The purpose of this paper is to identify the existing research gaps in LM as well as to group them into respective themes.

Design/methodology/approach

A systematic literature review (SLR) of peer reviewed journal articles in LM was carried out by the authors, based on four major publishers, namely, Emerald Online, Science Direct, Springer Link and Taylor & Francis. In total, 120 articles published in 30 journals during 2005–2016 were collected which revealed LM research gaps. A simple affinity diagram was applied in order to group the research gaps into logical themes.

Findings

A large number of research gaps are identified in the LM literature and meaningful themes of these gaps are also revealed.

Research limitations/implications

The SLR carried out by the authors is based on only four academic journal publishers and some of other publishers might have been missed out in this search. Excluding articles focusing on an individual Lean principle or tool/technique is also a limitation of the present SLR.

Practical implications

Researchers and practitioners can use the LM research gaps presented in this study for further development of LM methodology.

Originality/value

Presenting LM research gaps analytically and grouping them into meaningful themes, significantly differentiates the present SLR study from those published so far.

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.