The relative importance of improvement routines for implementing lean practices

Unveiling the Impact of Lean Leadership on Continuous Improvement Maturity: A Scoping Review

Purpose

Lean Management (LM) is a process improvement approach with growing interest from healthcare organizations. Obtaining a culture of continuous improvement is a primary objective of LM, and a culture of continuous improvement indicates a mature LM approach, and here leadership plays a central role. However, a comprehensive overview of leadership activities influencing LM maturity is lacking. This study aims to identify leadership activities associated with continuous improvement and, thus, LM, maturity.

Methods

Following the PRISMA guidelines, a scoping literature review of peer-reviewed articles was conducted in twenty healthcare management journals. The search provided 466 articles published up until 2023. During the selection process, 23 studies were included in the review. The leadership activities related to continuous improvement maturity were identified using the grounded theory approach and data coding.

Results

The analysis highlighted a total of 58 leadership activities distributed across nine themes of LM leadership. Next, analysing leadership activities concerning the different maturity levels revealed three maturity stages: beginner, intermediate, and expert. Based on the findings, we propose a framework that guides suitable leadership activities at the various stages of LM maturity. The framework provides leaders in healthcare with a practical overview of actions to facilitate the growth of the LM approach, and the related propositions offer academics a theoretical basis for future studies.

Conclusion

This review presents the first comprehensive overview of LM leadership activities in relation to continuous improvement and LM maturity. To enhance LM maturity, leaders are encouraged to consider their leadership style, (clinical) stakeholder involvement, alignment with the organizational strategy, and their role in promoting employee autonomy.

Necessary condition analysis (NCA): review of research topics and guidelines for good practice

Necessary condition analysis (NCA) is an increasingly used or suggested method in many business and management disciplines including, for example, entrepreneurship, human resource management, international business, marketing, operations, public and nonprofit management, strategic management, and tourism. In the light of this development, our work delivers a review of the topics analyzed with NCA or in which NCA is proposed as a method. The review highlights the tremendous possibilities of using NCA, which hopefully encourages other researchers to try the method. To support researchers in future NCA studies, this article also provides detailed guidelines about how to best use NCA. These cover eight topics: theoretical justification, meaningful data, scatter plot, ceiling line, effect size, statistical test, bottleneck analysis, and further descriptions of NCA.

Developing SME performance management practices: interventions for improving productivity

Purpose

The paper is a proof of concept (PoC) intervention study aimed for developing performance management (PM) practices in manufacturing small and medium-sized enterprises (SMEs) with the longer-term aim enabling the SMEs to improve their productivity. The intervention was designed and deployed by a collaborative quartet of academics, management consultants, accountancy firm and a commercial bank manager.

Design/methodology/approach

The paper firstly musters a set of initialising PM practices aligned to productivity improvement. These are utilised to design a knowledge transfer intervention for deployment with a set of manufacturing SMEs incorporating some associated productivity tools. The evaluation of the intervention utilised a case study approach founded on a logic model of the intervention to assess the development of the PM practices.

Findings

The intervention contributed to a partial development of the mustered practices and the productivity diagnostic based on the multi-factor productivity (MFP) abstraction and a data extraction protocol had the strongest impact. The study revealed the importance of the three interlaced factors: Depth of engagement, feedback opportunities and the intervention gradient (the increase of independent action from the participating SME's and the diminishment of the external intervention effort).

Research limitations/implications

The case study is based on a limited number of individual SME's, and within just the manufacturing sector.

Practical implications

SME businesses will require a more sustained programme of interventions than this pilot to develop PM capability, and depth of engagement within the SME is critical. Professional stakeholders can be utilised in recruitment of firms for intervention programmes. Business can start developing PM capability prior to PMS implementation using the tools from this programme.

Originality/value

The productivity diagnostic tool, based on a synthesis of MFP and the performance pyramid, an array of potential initialising practices for PM capability and discovery of potential mechanisms for PM practice development.

Establishing the interplay between lean operating and continuous improvement routines: a process view

Purpose

Building on the routine dynamics literature, this paper aims to expand our philosophical, practical and infrastructural understanding of implementing lean production. The authors provide a process view on the interplay between lean operating routines and continuous improvement (CI) routines and the roles of different actors in initiating and establishing these routines.

Design/methodology/approach

Using data from interviews, observations and document analysis, retrospective comparative analyses of three embedded case studies on lean implementations provide a process understanding of enacting and patterning lean operating and CI routines in manufacturing SMEs.

Findings

Incorporating the “who” and “how” next to the “what” of practices and routines helps explain that rather than being implemented in isolation or even in conjunction with each other, sustainable lean practices and routines come about through team leader and employee enactment of the CI practices and routines. Neglecting these patterns aligned with unsustainable implementations.

Research limitations/implications

The proposed process model provides a valuable way to integrate variance and process streams of literature to better understand lean production implementations.

Practical implications

The process model helps manufacturing managers, policy makers, consultants and educators to reconsider their approach to implementing lean production or teaching how to do so.

Originality/value

Nuancing the existing lean implementation literature, the proposed process model shows that CI routines do not stem from implementing lean operating routines. Rather, the model highlights the importance of active engagement of actors at multiple organizational levels and strong connections between and across levels to change routines and work practices for implementing lean production.

Creation of organizational knowledge through a model of standardization of production systems in the paper industry

Purpose

The purpose of this article is to propose a standardization model that contributes to the creation of organizational knowledge in the paper industry. This study was oriented to answer the question: how to create organizational knowledge through the standardization model of the paper industry’s production system?

Design/methodology/approach

This research was applied in the main production unit of the paper organization. The data were collected through the analysis of documents, systems and routines of the researched unit. In the research, the observation technique and direct documentation were used. For the operationalization of the research, the following phases were carried: understanding of the applied standardization model, literature review on the research topics, formulation of a standardization model and application of the model.

Findings

A model of standardization of production processes that contributes to the creation of organizational knowledge, in which a correlation of all its stages with the Knowledge conversion modes was found and validated through an applied research in the industry.

Research limitations/implications

This study is applied in a paper industry. In the survey, there is no comparison with other companies. The adaptation of the study in other industries and organizations can increase knowledge about the connection of standardized systems with knowledge conversion modes, adjusting them to other environments or other situations.

Originality/value

This study stands out for empirically testing, a standardization model that favors the creation of knowledge through the analysis of the various activities in a paper industry, providing a real connection between the knowledge management literature and the organizational environment. Standardization can represent an instrument of innovation in the most diverse types of industry, as long as it comes with a proposal for something new and better than the existing model.

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.

Role of personal anxiety in individual kaizen behaviour and performance: evidence from Japan

Purpose

This study examines the role of anxiety in kaizen behaviour and performance by empirically testing the influence of personal anxiety (state and trait) on individual kaizen behaviours (rule adherence, initiative and perseverance of effort), which, in turn, affect individual kaizen performance.

Design/methodology/approach

The data were obtained from a survey of 552 employees of four companies in Japan and analysed using structural equation modelling.

Findings

The results show that state anxiety has a significantly positive effect on rule adherence and kaizen performance. Trait anxiety positively influences employees' initiative and perseverance but has a significant negative effect on kaizen performance.

Originality/value

This study contributes to kaizen and continuous improvement theory by focussing on individual kaizen, which is considered to be as important as organisation-level kaizen and investigating the relevance of personal anxiety in individual kaizen behaviours and kaizen performance.

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.

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.

Learning lean: rhythm of production and the pace of lean implementation

Purpose

Why some assembly factories implement a lean program faster than others is an enduring puzzle. We examine the effect of a fundamental characteristic of every assembly factory—its rhythm of production.

Design/methodology/approach

We designed a multi-method study and collected data from a leading global equipment manufacturer that launched a lean program across its factory network. We use quantitative data gathered from internal company documents to test our hypothesis that production rhythm affects the pace of lean implementation. We then analyze qualitative data from interviews and factory visits to derive theoretical explanations for how production rhythm affects lean implementation.

Findings

Consistent with our hypothesis, we present evidence that factories with faster production rhythms implement lean faster than those with slower rhythms. This evidence is consistent with learning theories as well as the literature on organizational routines and forms of knowledge. We propose a theory of the relation between rhythm and learning in lean implementation.

Research limitations/implications

The hitherto unexplored relation between production rhythm and lean implementation raises intriguing questions for scholars and ushers new insights into how organizations learn to implement lean.

Practical implications

Organizations need to calibrate their expectations for lean implementation pace when their factories have widely different production rhythms and find ways to mitigate any adverse effects slower rhythms may have. Organizations can alleviate the unfavorable context of slower rhythms by inculcating practices in the factory that emulate the learning environment present in faster-paced factories.

Originality/value

We contribute novel quantitative and qualitative evidence that production rhythm affects lean implementation through learning-based mechanisms.

Tacit knowledge transfer and spillover learning in ramp-ups

Purpose

With shortening product life cycles and an increasing number of product variants, manufacturing firms perform more production ramp-ups. In this context, learning is crucially important to quickly achieve high production process quality and stability. The paper aims to discuss this issue.

Design/methodology/approach

Through a laboratory experiment, this study analyzes spillover learning between consecutive ramp-ups and how this phenomenon is influenced by tacit knowledge transfer through observation and imitation.

Findings

The results prove the existence of spillover learning between consecutive ramp-ups. Moreover, they provide evidence how tacit knowledge transfer through observation and imitation enhances learning of new tasks in consecutive production ramp-ups.

Research limitations/implications

Future research could focus on the specific psychological processes driving tacit knowledge transfer and spillover learning, a topic which is only touched upon in this paper.

Practical implications

The findings show that manufacturing firms should not only aim at reaching a steep learning curve during a single production ramp-up, but should also take into account the effects of spillover learning with regard to future production ramp-ups. Furthermore, the paper provides novel insights concerning the allocation of workers to production tasks with regard to previous experience when introducing new personnel and during ramp-up phases.

Originality/value

Previous evidence on the existence and characteristics of spillover learning in production ramp-up situations is not conclusive. This paper provides new and unambiguous insights by considering different organizational settings.

A case-based methodology for lean implementation in hospital operations

PURPOSE

Although there are general methodologies for lean implementation in manufacturing companies, a specific methodology for the implementation of lean healthcare in hospitals has not been addressed by the literature. Addressing this gap, the purpose of this paper is to develop a practice-driven methodology for implementing lean in hospital operations.

DESIGN/METHODOLOGY/APPROACH

Three case studies were conducted to collect evidence on the lean implementation process in Brazilian hospitals. From empirical evidence and literature, the implementation methodology was proposed and submitted to critical assessment by experts from the field.

FINDINGS

The process of lean implementation was very similar in all cases, triggered by strategic planning and operationalized by continuous improvement projects. On the other hand, in all cases, the lean implementation teams had to deal with employees' resistance. These findings were valuable inputs to the development of the implementation methodology. After refinement, it was proposed a feasible, useful and user-friendly methodology.

RESEARCH LIMITATIONS/IMPLICATIONS

The proposed methodology was raised from the practice through case study research. However, the proposed methodology was not fully applied, and the associated performance measures were not elaborated in this paper. Therefore, more case studies and applications will be necessary to generalize the findings.

PRACTICAL IMPLICATIONS

The methodology provides practical guidelines that support lean implementation in hospital operations. Although it demands adaptations for each specific hospital setting, this initial step may encourage hospital managers to start the lean journey.

ORIGINALITY/VALUE

This study addressed the gap in the literature regarding the lack of methodologies for implementing lean healthcare in hospital operations. The methodology synthesizes the knowledge, principles and tools of lean thinking that can be applied in hospital operations.