Understanding alignment between lean and agile strategies using Triple-A model

Contextual factors on Toyota Way and Agile Manufacturing: an empirical investigation

This research aims to examine the differences across selected contextual factors on the Toyota Way (TW), agile manufacturing (AM) and their sub-elements. These factors include firm size, nationality of firms, production approaches, IATF 16949 - an international quality management certification in the automotive industry, supplier tiers in supply chains, export levels, and import levels. A survey instrument was developed based on literature, then verified by experts and statistical techniques. ANOVA and independent samples t-test were used to explore the differences across contextual factors of 216 automotive part manufacturers on TW, AM, and their elements. It revealed that there were significant differences across firm size, nationality of firms, and export levels on overall TW, AM and most sub-elements. Insignificant differences across production approaches and IATF 16949 on overall TW, AM and their sub-elements were found. Firms with different contextual factors require different levels of TW, AM and sub-elements. Managers should apply TW and AM elements at suitable levels in accordance with their organizational contexts.This is one of the first studies to empirically investigate the differences across the contextual factors on TW, AM and sub-elements in the same paper from a socio-technical perspective. This study can be used as a basis for further research on integrative practices between lean and agile (leagile) manufacturing.

Understanding influence of supply chain competencies when developing Triple-A

Purpose

To be successful in the rapidly changing global business environment, supply chains (SCs) must be agile, adaptable and aligned (Lee, 2004), a practice known as Triple-A. Therefore, the purpose of this paper is to investigate the dimensions of Triple-A SCs and their concurrent impact on all three Triple-A components.

Design/methodology/approach

The relationship among these factors is analyzed through Smart PLS-structured equation modeling (PLS-SEM) for which data have been collected from 243 SC professionals working in manufacturing organizations.

Findings

The findings of this study reveal that the relationship between visibility and adaptability are directly significant but that the negative relationship between velocity and alignment is insignificant; however, indirectly these relationships have a positive impact using the mediating effect of agility over visibility and adaptability, velocity and alignment. However, the relationship of flexibility over SC Triple-A is positively significant, visibility over agility and alignment is positively significant and velocity over agility and adaptability is also positively significant, and each impact agility over adaptability and adaptability over alignment which is significant.

Originality/value

There is a shortage of empirical studies to date that empirically provide evidence of possible relationships among Triple-A and its key dimensions when attempting to obtain Triple-A. This is the first authenticated Triple-A SC conceptual framework that provides direction to better understand the dimension and significance of Triple-A.

Design framework for a lean warehouse – a case study-based approach

Purpose

This purpose of this study is to develop a simple framework for designing a warehouse incorporating lean principles. Multiple objectives like resource planning, material handling, storage, inventory management, including internal and external logistics, are considered.

Design/methodology/approach

A design procedure to incorporate lean principles for designing a warehouse for a complex multi-model production line has been proposed. The preferred standards and factors affecting warehouse design, the inputs and outputs of process flow characteristics, are incorporated into the design. Current and future state value stream mappings are drawn to bring out the challenges in the value flow.

Findings

The framework for designing a lean warehouse have been implemented and validated in a heavy machinery manufacturer. This framework will ease the work of the future lean-based warehouse designers to apply simple step-by-step processes to achieve the goal with the nearest accuracy. The steps followed can be summarized as defining the lean processes, making the lean process as the design base, collecting inputs like stock-keeping unit master, inventory and space details, and building the lean warehouse design with the step-by-step processes.

Practical implications

Practical tips on warehouse design have been explained focusing on the part volume, quantity handled, inventory and throughput. This will assist the practitioners in designing a lean warehouse and leading to an improved operational performance.

Originality/value

A simplified design procedure for designing a lean warehouse, along with a real-time case study has been enumerated in detail. Effective use of space and resources with lean tools and techniques lead to better storage and picking efficiency resulting in an overall reduction in cost.