Measuring lean readiness through the understanding of quality practices in the Turkish automotive suppliers industry

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.

Circular economy: a conceptual model to measure readiness for manufacturing SMEs

Purpose

Over the last decade, circular economy (CE) has gathered interest from both industrialists and academics alike. Whilst CE research is widespread in such areas as supply chain and larger organisations, there is limited research into how small to medium enterprises (SMEs) can prepare for adopting CE. There is no comprehensive readiness model for SMEs adopting CE. The purpose of this paper is to explore the literature on change readiness and generate knowledge to fill this gap by developing a conceptual model to measure change readiness for SMEs' adopting CE.

Design/methodology/approach

This study is based on a comprehensive literature review of change readiness models and frameworks. The paper reviews publications from Science Direct, Web of Science, Emerald, Scopus and Google Scholar. The readiness for change models and frameworks from the selected publications are evaluated and synthesised to develop a comprehensive conceptual model for change readiness for SMEs adopting a circular economy.

Findings

A readiness conceptual model is developed by incorporating several factors as precursors to readiness, i.e. individual/collective difference, structural, contextual factors and related barriers. Eleven factors make up the individual/collective difference. Three factors make up the structural and contextual factors.

Practical implications

This paper develops a conceptual model that can aid academics and practitioners in better understanding SMEs readiness to adopt CE.

Originality/value

This paper makes a unique contribution by proposing a comprehensive conceptual model of readiness for SMEs adopting CE.

Quality and innovation as drivers for manufacturing competitiveness of automotive parts suppliers

Purpose

The purpose of this paper is to identify the causal relationship between the independent variables such as process quality and product innovation in regard to the dependent variable of competitiveness, in the manufacturing sector of the automotive industry, specifically for Tier 1 auto parts manufacturing companies in the state of Nuevo León, México.

Design/methodology/approach

Based on a thorough review of the literature, an instrument was designed to measure the competitiveness of automotive industry manufacturing; it was applied to Tier 1 suppliers of automotive parts in the state of Nuevo León, México. Various statistical analysis tests were applied to the results; first, Cronbach's alpha to determine the reliability of the instrument, and next, a factor analysis to measure construct validity. In addition, a multiple linear regression analysis was carried out to identify the causal relationships between the variables analysed.

Findings

This study found that process quality as well as product innovation have independent and positive causal relationships with respect to competitiveness in automotive manufacturing.

Research limitations/implications

The limitations of this paper are its focus on a single manufacturing sector, application in a single country and small sample size.

Practical implications

Companies that supply automotive parts will be able to invest in the key elements of quality and innovation while focusing their efforts on reinforcing their competitiveness.

Originality/value

Auto parts suppliers will be able to perform specific actions to improve their quality processes through lean manufacturing and quality assurance practices and by designing new and innovative products that will enhance their competitiveness.

Lean-green performance management in Indian SMEs: a novel perspective using the best-worst method approach

Purpose

In a globalized environment, small and medium enterprises (SMEs) are facing formidable challenges. Not only do they have to keep up their profitability, but there is also a pressure from various stakeholders to add to their environmental and quality performance .The solution obviously lies in continuously adopting and improving upon lean-green practices in their operations. This work aims at identifying, classifying and building up a duly tested robust ranked-order model of such “enablers”, related to lean-green practices, that puts them (the enablers) in an order of being the most significant to being the least significant further to be accorded the same or similar weight in strategy formulation and implementation stage by Indian SMEs for enhancing their overall organizational performance.

Design/methodology/approach

The study identifies 20 enablers (12 lean and 08 green manufacturing enablers) through extensive literature review and experts' opinion survey and classifies them into three main categories. The ranking and significance of each of the main and subcategory enablers is evaluated according to its weight which is determined by the best-worst method (BWM) approach, one of the novel multi-criteria decision-making (MCDM) methods. Further, the results have been drawn after running accuracy check of the rankings (based upon optimal weights) and testing the robustness of the ranked-order model through sensitivity analysis.

Findings

The results of this study reveal that out of the three main category enablers, “operational performance enablers (E1)” and “quality performance enablers (E3)” are the most and the least significant enablers, while in the group of 20 subcategory enablers, “Kaizen (E17)” and “environment emission control (E28)” are the most and the least significant subcategory enablers, respectively.

Practical implications

The prioritization model or ranked-order model of the lean-green manufacturing enablers proposed through this study may serve as a standard model to managers to help them decide and allocate their efforts and resources accordingly in managing their operations. This will also help them adopt high-ranking lean-green manufacturing enablers in their firms and benchmark and standardize their existing practices accordingly, leading to greater competitive advantage.

Originality/value

The study identifies various green-lean manufacturing enablers in SMEs, classifies them into three main categories and ranks them using BWM approach. The findings of this study should be extremely relevant to managers, manufacturing engineers and practitioners in Indian SMEs from the perspective of developing deeper appreciation of these enablers as per their relative ranked importance to further formulating an effective and efficient strategy for their implementation resulting in optimal results.

Quality and lean practices synergies

Purpose

The purpose of this study is to investigate the relationship between investments in quality and lean practices, and their impact on factory fitness. Using concepts originating in the theory of swift even flow, this study asserts that manufacturers, in order to improve their production swiftness and evenness, must leverage the potential synergetic effects between quality and lean practices.

Design/methodology/approach

This research uses data from the Global Manufacturing Research Group (GMRG) survey project (with data collected from 922 manufacturing plants, across 18 countries). The constructs and measurement model were assessed using confirmatory factor analysis (CFA) and the hypotheses were tested using ordinary least square (OLS) models.

Findings

This study highlights that both investments in quality and lean practices have direct impact factory fitness. The results provide insights into the efficacy of the investments in manufacturing practices and their role in augmenting the operational performance. The investments in quality practices were found to enhance the efficacy of investments in lean practices, which in turn impact the factory fitness.

Practical implications

From a practical perspective, the study informs managers on how to leverage investment in quality practices to enhance the impact of lean practice on performance. The results provide empirical evidence to support management decision-making concerning the development of competences in quality and lean practices, which may create competitive advantage.

Originality/value

This study contributes to the quality and lean literature and provides empirical evidence of the synergetic effects between investments in quality and lean practices. The analysis offers a greater understanding of the mechanisms that can be used to maximise the impact of investments in lean practices, from a global perspective. The findings are important to the advancement of theory in operations management, as it integrates three research streams: quality practices, lean practices and swift even flow research.

Lean readiness within emergency departments: a conceptual framework

Purpose

The purpose of this paper is to develop a framework to assess the lean readiness within emergency departments (EDs) and identify the key quality practices deemed essential for lean system (LS) implementation.

Design/methodology/approach

An extensive review of the lean healthcare literature was conducted, including LS implementation within the healthcare sector (both generally and in EDs), best ED quality practices, essential factors for LS implementation within healthcare and lean readiness assessment frameworks. The authors identified six main categories from a literature review (top management and leadership, human resources, patient relations, supplier relations, processes and continuous improvement (CI)), and validated these based on experts’ opinion.

Findings

Several factors were identified as crucial for EDs, including top management and leadership, human resources, patient relations, supplier relations, processes and CI.

Research limitations/implications

The framework has not yet been tested, which prevents the author from declaring it fit for EDs.

Practical implications

This framework will help ED managers determine the factors that will enable/hinder the implementation of LSs within their premises.

Originality/value

To the author’s knowledge, this is the first lean readiness assessment framework for EDs and one of the few lean readiness assessment frameworks in the literature.

Total quality environmental management: adoption status in the Chinese manufacturing sector

Purpose

To address the critical sustainability challenges currently faced by China, manufacturers in this country have committed to improve their environmental performance. To support this commitment, evidence suggests that Chinese manufacturers have mainly turned to the implementation of environmental management approaches such as ISO 14001, cleaner production, green supply chain management, circular economy and green lean. However, the adoption of other approaches such as total quality environmental management (TQEM) by Chinese manufacturers is less clear. The purpose of this paper is to fill this gap by providing light into fundamental issues regarding the implementation of TQEM in the manufacturing sector of China.

Design/methodology/approach

A survey-based exploratory study was conducted based on 119 Chinese manufacturing companies, and the data obtained were analysed using a combination of descriptive and inferential statistics.

Findings

The results revealed that in general, there is less awareness of TQEM in the Chinese manufacturing sector than other environmental and quality/operations improvement approaches such as green supply chain management, reverse logistics, ISO 9000, Six Sigma and lean Six Sigma. Thus, its degree of implementation is also lower than these approaches as well as ISO 14001. The results also indicate that although a company’s size is not associated with the implementation of TQEM, it is mainly large organisations and those that have adopted TQM those which will be mainly aware and have implemented TQEM. The study also reveals the drivers, results and challenges of TQEM implementation.

Originality/value

The paper extends the currently limited knowledge on TQEM, and its results are beneficial for managers who aim at effectively adopting TQEM to simultaneously improve the environmental, operational and financial performance of their organisations. The paper can also motivate organisations not currently embarked on the “green wagon” to contemplate the benefits that implementing TQEM, or any other environmental management approach, may bring to their operations and business.

Lean readiness – the case of the European pharmaceutical manufacturing industry

Purpose

The purpose of this paper is to assess the quality practices of European pharmaceutical manufacturers to determine the level of readiness of this industrial sector to implement and/or sustain lean manufacturing (LM).

Design/methodology/approach

An assessment framework developed by Al-Najem et al. (2013) was adapted to evaluate how ready European pharmaceutical manufacturers are to implement and/or sustain LM. Therefore, the lean readiness (LR) level of these organisations was assessed through six quality practices related to LM. These included: processes, planning and control, human resources, top management and leadership, customer relations, and supplier relations. One research question and three hypotheses were formulated and tested using a combination of descriptive statistics and non-parametric Mann-Whitney tests. Data were collected through a survey questionnaire distributed to 310 European pharmaceutical manufacturers and responded by 37 of these organisations.

Findings

Overall, the results of this study indicate an inadequate level of LR for the participating firms. Simultaneously, it was concluded that factors such as company size, type of relationships with suppliers and ISO 9000 certification do not have an effect on the quality practices, and hence LR level, of European pharmaceutical manufacturing organisations.

Practical implications

This study provides crucial information regarding the LR level of European pharmaceutical manufacturers, which can now be aware of the areas in their practices that require further improvement towards a successful lean journey. Simultaneously, organisations in the pharmaceutical sector that intend to implement LM can consider the results of this study and evaluate their readiness level. Managers can, therefore, refer to this research and use it as a platform to take better decisions regarding what quality aspects of their operations need to be enhanced to successfully deploy or sustain a lean strategy.

Originality/value

This research is one of the very few studies that have focussed on evaluating whether the European pharmaceutical manufacturing industry is ready to successfully implement or sustain LM. Therefore, this research expands the limited existent body of knowledge of LM in this industry.

Implementation of lean supply chain: an empirical research on the effect of context

Purpose

The purpose of this paper is to empirically investigate the effect of a set of contextual variables on the implementation of lean supply chain (LSC) practices. The authors do that by investigating one main research question: “how do the contextual variables (i.e. plant size, supply chain level, level of onshore suppliers and age of the LM initiative) influence on the degree of adoption of LSC practices?”

Design/methodology/approach

To this end, the authors collected data from 115 companies from different sectors located in Southern Brazil. Data collected was analyzed by means of multivariate techniques. The authors tested if the frequency of observations for each contextual variable was associated to the implementation levels of the LSC practices.

Findings

The evidences suggest that supply chain context significantly impacts the likelihood of implementing LSC practices. In particular, the influence of tier level, plant size and larger experience in implementing LM seems to be substantial across a wide mix of practices. On the other hand, results indicate that contexts in which companies are still beginners at the lean journey and their level of onshore suppliers appear to be less pervasive than previous empirical researches imply.

Originality/value

The implementation of LSC practices entails a different business model, in which improved profits arise from the cooperation rather than bargaining or imposing power over supply chain partners. However, not all organizations should implement the same set of practices, since the adoption of any specific management practice depends upon a set of contextual variables. The understanding of the relationship between the level of adoption of LSC practices and the contextual variables helps to anticipate occasional difficulties and sets the proper expectations along the implementation.