Research gaps in Lean manufacturing: a systematic literature review

The integration of lean and human resource management practices as an enabler for lean deployment –a systematic literature review

Purpose

The current research aims to map and investigate how human resource management and lean practices can be integrated. This investigation will help identify the HRM aspects critical in the success of lean initiatives while exploring the research gaps in the existing literature. The review also aims to delineate the benefits and challenges of integrating lean with HRM systems to discuss further research and practice areas.

Design/methodology/approach

This study utilizes a systematic literature review method to identify and synthesize the existing literature. As part of the process, a protocol that provided a plan for the review was followed, including the research questions and the data to be extracted.

Findings

The study results indicate that aspects of HRM practice and policies such as training and development, teamwork, motivation, communication, leadership, are key enablers of lean initiative deployment and success. The benefits of the integration of human resources with lean can help in lean training and development, communication of lean initiatives and successes, allocating and hiring continuous improvement personnel, and supporting leadership in lean deployment. Challenges to integrating lean and HRM practices included lack of integration and collaboration between disciplines. Further exploration areas in successful lean deployment would be practical longitudinal case studies on lean deployments with human resource (HR) partnerships and involvement.

Practical implications

This review paper has crucial implications for practice relating to, integration of lean with HRM structures and tailoring HRM initiatives to ensure the success of lean deployment and reduce risks of failure.

Originality/value

The systematic literature review study conducted in this paper is the first of its kind to integrate and map the HRM concepts that can be integrated with Lean to deploy the initiative successfully. This mapping is critical for ensuring the success of lean methodologies within an organization and paves the way for future research. In addition, managers and organizations can find support and guidance from this study to focus on vital areas of partnership between their lean and HR programs.

Improving operational performance of manufacturing SMEs: the interactive effect of technical and human lean practices

Purpose

Although understanding how different resources are interconnected within firms is important, there are few studies that have focused on this area. This study aims to explore the unique and interactive effects of technical lean practices (TLPs) and human lean practices (TLPs) on the operational performance (OP) of manufacturing SMEs in Yemen, a less developed country (LDC).

Design/methodology/approach

Depending on data collected from 318 manufacturing SMEs in Yemen, the relationships in the proposed model were tested using hierarchical regression analysis via PROCESS Macro V. 3.5 in SPSS.

Findings

The results show that both TLPs and HLPs have unique effects on OP of SMEs. More importantly, both TLPs and HLPs have synergistic effects on OP.

Practical implications

The study would be of interest to Lean practitioners, as the results of this study can be used in firms to put a focus on how TLPs and HLPs have to interact when it comes to the successful implementation of lean manufacturing (LM).

Originality/value

Although research interest in LM is increasing, the interactive effects of TLPs and HLPs remain to be understood. This study provides an initial empirical evidence for performance outcomes from the interaction between TLPs and HLPs of SMEs in LDCs such as Yemen. Most of the previous studies on lean practices have focused on SMEs in developed countries, which may not fully apply to LDCs such as Yemen. This is helpful for SMEs' managers in the context of LDCs to understand how TLPs can further improve OP when interacting with HLPs.

The Theoretical and Practical Evolution of Customer Journey and Its Significance in Services Sustainability

In the scientific literature, the concept of the “customer journey (CJ)” has only recently been introduced, and, accordingly, it lacks robust empirical evidence. Still, the number of papers concerning the CJ has increased exponentially in recent years. The aim of this paper is to fully represent the available CJ research in services and highlight its importance for service sustainability. Since the current CJ literature mainly includes qualitative data, this paper is a narrative review based on the Preferred Reporting Items for Systematic Review and Meta-Analysis checklist. The systematic literature review conducted by the authors is based on peer-reviewed articles published up until 2019. The main findings mostly concern the conceptualization of the CJ at a theoretical and practical level—CJ definitions and evolution for the former and customer journey mapping for the latter—as well as to present new perspectives of the examined terms in the services peer-reviewed bibliography and verify their contribution to service sustainability. CJ monitoring helps the development of a more sustainable service because it advances service innovation and effective channel management. Furthermore, it leads managers to understand their customer decision-making process and better allocate their resources by establishing a sustainable service design throughout the various service phases.

Impact of Hoshin Kanri on lean management: a case study in the food retail industry

Purpose

This study aims to describe how the Hoshin Kanri (HK) strategic methodology facilitates implementation of lean management (LM), achieving greater integration of the strategic and operational levels, resulting in higher performance level.

Design/methodology/approach

The authors conducted an in-depth case study of a top-10 Spanish food retail company with experience in HK and LM. First, the authors conducted 17 semi-structured interviews with the management team. Second, the authors analyzed all minutes from meetings of the key management entities for HK monitoring over a period of 3 years (2016–2019). Third, the authors evaluated the reports and key scorecards for the same period. Finally, authors visited the operating facilities and attended multiple team management meetings.

Findings

This study demonstrates that deploying HK creates the strategic ecosystem for operations management that facilitates successful implementation of LM. By sharing common cultural concepts, both methodologies generate faster transformation of the organization and thus push it towards its strategic objectives with more determination and better performance.

Originality/value

The lack of strategic alignment is one of the most important reasons for LM failure. Although HK is a strategic methodology that facilitates this alignment, a gap exists in the literature on the benefits of HK for implementation of continuous improvement initiatives such as LM. Our research shows how HK enables a participative connection between the strategic and operational areas of the firm that reinforces the fundamental elements of LM. Employee involvement, widespread use of plan-do-check-act (PDCA) methodology and multidisciplinary work (among other effects) make HK a key element for successful implementation of LM.

A Sustainable Productive Method for Enhancing Operational Excellence in Shop Floor Management for Industry 4.0 Using Hybrid Integration of Lean and Smart Manufacturing: An Ingenious Case Study

In industry 4.0, industry individuals implement lean and smart manufacturing to improve shop floor management systems. Shop floor management is used to control operational performance and enhance production within limited constraints. Various shop floor management approaches are used in the present scenario of industry 4.0, and mainly include value stream mapping, total productive maintenance, Internet of Things, artificial intelligence, machine learning, and fuzzy logic. The present research aims to develop an open innovation method to achieve sustainability in shop floor management systems in industry 4.0 by using lean and smart manufacturing concepts. The proposed method has been validated by an enhancement obtained in a real case of the shop floor management system in industry 4.0. The authors are confident that the proposed method would provide sustainability in the shop floor management system within limited constraints in industry 4.0.

From Lean Production to Lean 4.0: A Systematic Literature Review with a Historical Perspective

Over recent decades, the increasing competitiveness of markets has propagated the term “lean” to describe the management concept for improving productivity, quality, and lead time in industrial as well as services operations. Its overuse and linkage to different specifiers (surnames) have created confusion and misunderstanding as the term approximates pragmatic ambiguity. Through a systematic literature review, this study takes a historical perspective to analyze 4962 papers and 20 seminal books in order to clarify the origin, evolution, and diversification of the lean concept. Our main contribution lies in identifying 17 specifiers for the term “lean” and proposing four mechanisms to explain this diversification. Our research results are useful to both academics and practitioners to return to the Lean origins in order to create new research areas and conduct organizational transformations based on solid concepts. We conclude that the use of “lean” as a systemic thinking is likely to be further extended to new research fields.

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.

Practical implications of cost of quality: a systematic literature review

Purpose

The present study focuses on the cost of quality (CoQ) based on which organizations can evaluate their quality-related activities in economic terms. The purpose of the study is to identify the CoQ practical implications as well as to group them into logical themes.

Design/methodology/approach

A systematic literature review (SLR) was conducted based on well-known academic publishers, such as Emerald Insight, Elsevier/ScienceDirect, SpringerLink, Taylor & Francis, Wiley and Scopus. Sixty-seven peer-reviewed journal articles in the field of CoQ were collected, which were published between 2010 and 2019. The “affinity diagram” was applied to group the practical implications identified into logical themes.

Findings

A plethora of CoQ practical implications were identified and grouped into the following meaningful themes: benefits of CoQ measurement, effects of CoQ, business sectors measuring CoQ, factors influencing CoQ measurement, CoQ elements, future research in CoQ and the role of government.

Research limitations/implications

The limited number of the publishers and keywords used to search for the articles of interest, as well as the subjectivity of grouping the large number of the practical implications into themes are the main limitations of the present study. These limitations constitute the basis upon which future literature review studies can be designed.

Practical implications

The present study by presenting analytically and in summary (through the themes revealed) the CoQ practical implications, provides all the respective available literature in a single study for the benefit of practitioners and academics. Thus, clear and straightforward guidelines are given to practitioners with regard to CoQ issues and academics with regard to research topics of high interest.

Originality/value

No previous SLR study focusing on analyzing the practical implications of CoQ has been published so far.

Cleaner production practices at company level enhance the desire of employees to have a significant positive impact on society through work

Implementation of cleaner production practices (CPP), service quality (SQ) and corporate social responsibility (CSR) is often studied at organizational level. A number of studies on trio have reported it's significant impact on overall organizational performance and profitability across the globe. However, not much is studied about the individual level micro influence of these constructs on employee engagement (EE), organizational pride (OP), organizational identification (OI) and "desire to have a significant impact through work" (DSIW). Therefore, this study presents a comprehensive framework for assessing the impact of the implementation of CPP, SQ and CSR on EE, OP, OI and DSIW. Data collected from 320 non-managerial staff members employed at a garments manufacturing company in Pakistan was analyzed using partial least square (PLS) approach. Findings revealed that the implementation of CPP, SQ and CSR plays an important role in shaping EE, OP, OI and DSIW in the garments manufacturing industry. Further, it is found that the implementation of CPP has a non-significant impact on SQ. Additionally, results of the importance-performance map analysis (IPMA) have also confirmed that the implementation of CPP at company level has shown a highest importance and performance amongst all the latent constructs proposed as predictors of DSIW in the garments manufacturing industry. These findings are a step forward and unique contribution of this study in the domain of CPP, SQ, CSR, EE, OP, OI and DSIW.

Exploring the dark side of Lean: a systematic review of the lean factors that influence social outcomes

Purpose

Lean has shifted over the years from a set of tools to implement to a human-centric approach concerning both hard and soft factors. However, there is a limited research on these soft factors and how they influence companies performance and social outcomes on the one hand and how they enable the hard factors on the other hand. Taking this as a valuable opportunity, the purpose of this paper is to present the key motivating factors and key gaps in the literature as an agenda for future research.

Design/methodology/approach

A systematic methodology to identifying the literature on social outcomes and factors in Lean is presented. Web of Science, EBSCO, Emerald, Science Direct, Google Scholar and the top journals were searched, and 158 papers were identified.

Findings

The systematic review helped the authors to identify the evolution, current trends, research gaps and an agenda for future research for exploring social outcomes in Lean and the factors mediating them. These factors are grouped and presented.

Practical implications

The implications of this work include understanding for managers and professionals how both soft and hard factors in Lean are related and that for a sustainable implementation, the whole system must be observed. This work could serve as a valuable resource that depending on the execution of Lean, either positive outcomes will emerge or even negative outcomes, referred to as “The Dark Side”.

Originality/value

This paper presents an extended survey on the factors in Lean mediating both companies’ performance and social outcomes. The authors also believe that this is possibly the most comprehensive systematic literature review on the topic and will set the foundation for various research avenues based on the key findings of this study.

Performance management of SMEs: a systematic literature review for antecedents and moderators

Purpose

The purpose of this study is to gain insight into existing empirical studies on performance management of small and medium-sized enterprises (SMEs). It categorizes the main antecedents for SMEs’ performance, the dimensions of SMEs’ performance and all variables used as moderators in the conceptual relationships.

Design/methodology/approach

This study undertakes a systematic literature review of 58 articles published in 33 peer-reviewed academic journals from 2000 to 2020 followed by a synthesis of individual studies to analyze the trends and background of research into SMEs.

Findings

A new academic conceptual model was developed grounded in selected theoretical lenses to advance our understanding of the different categories of antecedents, moderators and SMEs’ performance dimensions.

Research limitations/implications

The author has provided a future research agenda in the context of SMEs. Future studies may investigate the role of different categories of determinants, the influence of key cultural values, the digital capability in SMEs and the Internet in the internationalization of SMEs.

Practical implications

This paper offers a framework for both practitioners and scholars in thinking about those factors that may be critical for success in SMEs.

Originality/value

This is a systematic review that suggests a new conceptual model of what existing empirical studies have found on SMEs. It can be used to influence thinking and research design in the area of SMEs’ performance and success.

Value stream mapping in education: addressing work stress

Purpose

Teachers of primary education experience high levels of stress but lack rational coping strategies to reduce their work stress. The paper develops a value stream mapping for education approach and examines its use as a rational coping strategy for teams of teachers and other employees to overcome work-related stressors.

Design/methodology/approach

The research process consists of two phases. First, a value stream mapping approach for education is developed, based on literature research. Next, the approach is validated in an action research study to reduce work stress of teachers in educational services. The processes that have been selected by the teachers relate to coping with increased variety, long and uncertain throughput times and unclear specifications.

Findings

Value stream mapping for education (VSM4EDU) is a well-structured improvement method based on principles of visualization, participation and process thinking, which helps teachers without background in lean thinking to analyse their processes. Using this method has enabled the team to develop rational coping strategies to reduce their work-related stress.

Research limitations/implications

VSM4EDU has been validated using action research at a single school, which implicates deep insight, but further testing at other schools is welcome. Moreover, VSM4EDU has not been used to develop a future state map.

Practical implications

Value stream mapping is useful in educational settings as long as the educational context is respected in the approach.

Social implications

VSM4EDU empowers teachers and helps to develop co-operation in teams.

Originality/value

The validation of value stream mapping for education is well-documented and original.

Considering Random Factors in Modeling Complex Microeconomic Systems

Within the framework of a model describing real-functioning association of three enterprises, numerical calculations of economic dynamics parameters considering fluctuating market demand for the goods were performed. A methodology was suggested for approximated consideration of both seasonal and random demand fluctuations at the market of textile garments; the main steps of the suggested methodology were described. The main exogenous random factors within this model include, as stated above, the volume of market demand for the goods produced by the enterprises of the group. The basic volume of market demand is considered at the average actual level according to the results of the enterprises’ analysis, and additionally we take into account the influence of non-price factors, such as random changes in the consumers’ tastes, consumers’ income, and other random factors on the market demand. By volume of market demand, we consider the total amount of goods produced by the enterprises of the group that all consumers are willing and able to purchase at a specific price in a marketplace. The calculations were made based on actual values of external economic parameters, such as labor cost, product prices, etc. Influence of the market demand fluctuations on the companies’ activity has been illustrated both numerically and graphically, allowing the analysis of the impact of exogenous parameters on the companies output and profits. The suggested approach creates a basis for further analysis of the impact of random factors of a similar nature, i.e., stochastic shocks related to the level of interest rates, shifts and turnabouts in the social environment, as well as the market transformations due to annual/seasonal epidemics.

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.

Future research avenues of cost of quality: a systematic literature review

Purpose

The purpose of this paper is to identify the future research suggestions which have been made by several authors with regard to cost of quality (CoQ) and to group them into respective themes.

Design/methodology/approach

This study was based on a systematic literature review (SLR) of 97 peer-reviewed journal articles in the field of CoQ published in well-known academic databases, such as Emerald, Elsevier, SpringerLink, Taylor & Francis, Wiley and Scopus. The time horizon for reviewing the literature was 9 years, particularly in the period between 2010 and 2018. The “Affinity diagram” was applied to group the future research suggestions into logical themes and the “Pareto diagram” to further categorize and prioritize these themes.

Findings

A plethora of future research suggestions identified in the literature are analytically presented. Moreover, the analysis showed that the future research suggestions in the field of CoQ can be grouped under eleven meaningful themes, which are further categorized into two broad categories, meaning the vital and the useful.

Research limitations/implications

This SLR was based on only fully accessed English articles published in international, peer-reviewed journals of the selected publishers. The restricted number of keywords used and the subjectivity in applying the “affinity diagram” are also limitations of this study.

Practical implications

This paper provides insights into the future research perspectives in the field of CoQ. Thus, this analysis can serve as a resource for both researchers and practitioners to further develop this area according to the future research suggestions and the respective themes revealed.

Originality/value

To the best of the authors' knowledge, this is the first SLR presenting and analyzing the future research suggestions of CoQ.