A literature review of empirical research methodology in lean manufacturing

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.

A literature review on total quality management (models, frameworks, and tools and techniques) in higher education

Purpose

The purpose of this paper is to analyze the evolution of total quality management (TQM) models, frameworks, and tools and techniques in higher education (HE) over the last thirty years from 1991 till 2020, based on a literature review

Design/methodology/approach

30 articles from 52 journals were used to perform this detailed literature review. For the detailed analysis, the focus was only on articles related to TQM in higher education and specifically related to models, frameworks and tools and techniques. The study has investigated the growth of research articles, research streams, research methodologies, models and frameworks in the higher education sector and tools and techniques related to those.

Findings

This review addresses the progress and gaps in the application of TQM in HE, including the shift in global research in this area from the USA and Europe to Asia in recent years. The articles have been classified into four research methodologies and two research streams which have been reviewed in detail. The findings include reasons for multiple models/frameworks in HE proposed by researchers over the years and the importance of tools and techniques used in TQM implementation.

Originality/value

This study, which tries to bring a perspective to the main trends in TQM application to higher education wrt models, frameworks, tools and techniques over the last thirty years, is expected to add to the body of knowledge in this area and help future researchers to focus on the relevant areas identified in this paper.

Total Quality Management in higher education: a literature review on barriers, customers and accreditation

Purpose

The purpose of this paper is to analyze the evolution of Total Quality Management (TQM) in terms of barriers, customers and accreditation in higher education (HE) over the last three decades (1991–2020) using literature review to establish the current state.

Design/methodology/approach

A total of 137 articles across 55 journals were consolidated for this review specifically focused on TQM (barriers, customers and accreditation) in HE. The investigations were carried out to identify the chronological growth of articles, research streams and methodologies. The articles were classified based on four research approaches and three research streams which have been reviewed in detail.

Findings

Considering the rapid growth in the HE sector and the concerns over reduction in quality of education especially in developing countries, the importance of TQM in HE is immense. The findings include identification of the barriers to successful TQM implementation, the need for alignment of TQM objectives of higher educational institutions (HEIs) and identified target customer(s) with the selected model/framework and the impact of accreditation/certification in the attainment of TQM.

Originality/value

This study which tries to bring a perspective to the main trends in TQM application to HE with respect to barriers, customers and accreditation over the last three decades is expected to add to the body of knowledge in this area and help future researchers to focus on the relevant areas identified in this paper.

Improving high lean team performance through aligned behaviour-value patterns and coactive vicarious learning-by-doing

Purpose

Why are some lean workfloor teams able to improve their already high performance, over time, and others not? By studying teams' and leaders' behaviour-value patterns, this abductive field study uncovers a dynamic capability at the team level.

Design/methodology/approach

Various methods were employed over three consecutive years to thoroughly examine five initially high-performing lean workfloor teams, including their leaders. These methods encompassed micro-behavioural coding of 59 h of film footage, surveys, individual and group interviews, participant observation and archival data, involving objective and perceptual team-performance indicators. Two of the five teams continued to improve and perform highly.

Findings

Continuously improving high lean team performance is found to be associated with (1) team behaviours such as frequent performance monitoring, information sharing, peer support and process improvement; (2) team leaders who balance, over time, task- and relations-oriented behaviours; (3) higher-level leaders who keep offering the team face-to-face support, strategic clarity and tangible resources; (4) these three actors' endorsement of self-transcendence and openness-to-change work values and alignment, over time, with their behaviours; and (5) coactive vicarious learning-by-doing as a “stable collective activity pattern” among team, team leader, and higher-level leadership.

Originality/value

Since lean has been undertheorised, the authors invoked insights from organisational behaviour and management theories, in combination with various fine- and coarse-grained data, over time. The authors uncovered actors' behaviour-value patterns and a collective learning-by-doing pattern that may explain continuous lean team performance improvement. Four theory-enriching propositions were developed and visualised in a refined model which may already benefit lean practitioners.

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.

Systematic analysis of the methodological structure of the lean literature

Purpose

The purpose of this paper is to analyse and evaluate the methodological structure of the lean literature, so that its characteristics and influence among academics and practitioners might be better understood. The authors define “methodological structure” to be comprising six categorical components: publication category, degree of methodological disclosure, research strategies and data collection instruments (DCIs), type of data collected and analysed and type of research informants.

Design/methodology/approach

This study is a systematic bibliometric analysis of the lean literature. It has a two-stage research design. The first stage involves the identification of the top 50 most highly cited publications on “Lean”, with the resultant reference details being entered into a focal population set (FPS) spread sheet. The second stage involves coding and adding the six component fields of the methodological structure for each of the FPS entries. Both citation analysis (CA) and publication counting are then used to analyse patterns in these six components of methodological structure.

Findings

The top 50 publications in the FPS represent over 52,700 citations. All are either journal papers or books, but books are the most influential. Based upon this FPS sample, the lean literature is found to be both largely atheoretical in nature and also methodologically weak. Over half of the FPS publications are viewpoint-type publications and 46% have no methodological disclosure. The lean literature is predominantly qualitative in nature. Where disclosed, the most common research strategy is the case study and the most common DCI is the interview. High- and mid-level managers are the most frequently encountered research informants, while shop floor workers are infrequently used.

Originality/value

This paper starts with the most extensive known systematic review of systematic reviews of the lean literature; the result of which is the characterisation of a number of gaps in this body of knowledge. One of these gaps is the lack of any previous CA. The paper then proceeds to address this gap by providing the first CA within the lean literature. This is also the most comprehensive known CA within the field of operations and supply chain management more generally. As a consequence of this analysis, previously unknown patterns and insights into the methodological structure of the lean literature are revealed.

Proposing a Supply Chain Collaboration Framework for Synchronous Flow Implementation in the Automotive Industry: A Moroccan Case Study

The present paper reports on studying synchronous flow implementation, as a lean supply chain tools, through a collaborative relationship with suppliers. This involves consolidating with a new contribution to the development and application of a supply chain collaboration framework between automotive constructor and first-tier equipment suppliers to achieve the synchronous flow of components. The objective is to provide the automotive companies with a decision-making tool for selecting strategic suppliers to collaborate with, examining the collaboration context in terms of motivators, drivers, and barriers and evaluating the collaboration performance. Therefore, our contribution is structured as follows. As a first step, an overview of papers reporting on collaboration, lean supply chain, and synchronous flow is provided to identify the key elements of successful collaboration relationships. As a result, a preliminary framework is elaborated. The second step described the case study of a leading automotive firm “RENAULT” and its suppliers in Morocco. Based on semi-structured interviews conducted with participants from these companies, the preliminary framework was improved. The next section discusses the obtained results as well as the improved framework. Finally, conclusions and suggestions for further works are included.

Changes in communication patterns when implementing lean

Purpose

This paper explores the changes in communication patterns when companies implement lean, and how those changes relate to implementation success.

Design/methodology/approach

This is a multiple-site case study involving four business units of a manufacturing company in South America, including two repeated measurement instances separating 24 months for approximately 600 direct workers and 65 supervisors. The analytical models include social network analysis measures and Ordinary Least Squares regression.

Findings

When companies implement lean, (1) teams have a higher frequency of communication among members; (2) teams become more decentralized; (3) teams communicate more with supervisors and (4) supervisors communicate more amongst themselves and collaborate more. Also, (5) better performing teams change more pronouncedly.

Research limitations/implications

The study contains data for four business units but within only one company, limiting the external validity of the conclusions. The sample was predominantly male. Participant attrition and other potential covariates not included in the study can be additional limitations.

Practical implications

Lean implementations could be practically helped by managers by embracing and supporting the more intense communication patterns associated with lean success, and alternatively, they could proactively detect barriers in communication by measuring how these patterns change or fail to change and try to unlock communication by working on those barriers and supply communications infrastructure and opportunities for collaboration to try to boost the chances of success.

Originality/value

This is to our knowledge the first study measuring communication networks from the point of view of team members and low-level supervisors in lean implementations. This is also the first study showing that communication patterns change more rapidly in more successful teams, and also that communication pattern changes when implementing lean can be an indicator of success.

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.

Assessing lean implementation and benefits within Indian automotive component manufacturing SMEs

Purpose

The purpose of this paper is to investigate the status of lean manufacturing in Indian automotive sector, component manufacturing industries in terms of lean adoption, benefits, motivation, and challenges of implementing lean manufacturing practices.

Design/methodology/approach

The research objectives were achieved by conducting a qualitative multicase study approach. Fourteen Indian automotive component manufacturing small and medium-sized enterprises (SMEs) were chosen based on their different product offerings as well as differing approaches to the introduction and implementation of lean initiatives. Data were collected through in-depth, semistructured interviews supported by shop-floor observations.

Findings

The findings from the present study suggest that some of the participating automotive component manufacturing SMEs have a relatively good understanding of lean concepts and philosophy. However, there is room for further improvement for most SMEs. Major top five lean practices being implemented were found to be cellular manufacturing, total productive maintenance, 5S, work standardization, and quality management practices. Also, leadership and organizational culture were found to be crucial factors for the success of lean manufacturing.

Research limitations/implications

The fact that the data collected for the research study is based on subjective business evidence obtained from company representatives comprises the main limitation of the present study. So, the results should be considered with caution, as far as the lean adoption in Indian automotive component manufacturing sector is concerned.

Practical implications

Based on the present study, suggestions can be made regarding the successful adoption of lean principles, not only for the participating SMEs but also for the whole of the automotive component manufacturing sector. More specifically, by determining the strength and weakness of automotive component manufacturing SME's effort 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

This paper explores the status of lean adoption in Indian automotive component manufacturing SMEs. Considering the unique characteristics of the automotive component manufacturing industry, the present research would be helpful for making strategies to implement lean in automotive component manufacturing industry setups.

Revolution or 30-year fad? A role for I-O psychology in Lean management

Lean management and related ideas have had a significant impact on organizations throughout North America and the world. Despite its popularity and impact, I-O psychologists have largely neglected Lean as a research topic and few I-O psychologists engage in applied practice in the area. In this focal article, we provide a working definition of Lean and present examples of Lean’s influence. Next, we outline possible reasons to explain I-O psychologists’ indifference to Lean. Finally, we provide some topic areas that I-O psychologists can use to contribute to the Lean literature. By using I-O psychologists’ skill in measurement and evaluation, along with our considerable organizational theory, we believe that I-O psychology can improve Lean and broaden their impact. We hope this focal article will inspire I-O psychologists to reconsider a research and practice area that they have previously ignored. In addition, we hope that this article causes I-O psychologists to reflect on their role to play in addressing popular management trends.

Lean bundles in health care: a scoping review

PURPOSE

The purpose of this paper is to review original research on lean management (LM) in health care to identify potential research gaps and present recommendations for future research. The paper also discusses the current state of implementing LM practices in health care. In addition, it presents and highlights "lean bundles" imported from manufacturing, namely, total quality management (TQM), human resource management, just-in-time and total productive maintenance, as a potential implementation strategy of LM in hospitals to optimize overall health care performance.

DESIGN/METHODOLOGY/APPROACH

The scoping review was conducted based on the guidelines specified by Arksey and O'Malley (2005). Relevant included studies were retrieved by searching various electronic databases. The PRISMA guidelines were applied to identify and select eligible studies.

FINDINGS

The majority of previous studies used selected practices to measure LM in health care. In most cases, these practices reflected a narrow and biased view of LM. Lean bundles which comprehensively view LM and reflect all its aspects have rarely been discussed in the health care literature. Evidence about the contribution of lean bundles to hospital performance needs to be addressed in future studies.

PRACTICAL IMPLICATIONS

This paper demonstrates the implementation of the four lean bundles in hospitals. It argues that, instead of adopting one dimension or selected practices of LM, hospitals viewing LM as a comprehensive multi-dimensional approach through the adoption of the four lean bundles are expected to maximize their performances.

ORIGINALITY/VALUE

This is one of the first works to comprehensively review and discuss lean bundles in the context of health care. It argues that the adoption of the four lean bundles by hospitals will enable them to yield the maximum LM performance benefits. In addition, a proposed survey questionnaire based on the literature review is provided to assist researchers in conducting future empirical studies.

Lean-excellence business management for manufacturing SMEs focusing on KRI

Purpose

The purpose of this paper is to develop an effective framework for implementing Lean strategies in small- and medium-sized enterprises (SMEs) in the Kurdistan Region of Iraq (KRI).

Design/methodology/approach

Based on the integration of LM tools and techniques with the Malcolm Baldrige National Quality Award (MBNQA) criteria a systematic Lean implementation framework for manufacturing SMEs has been proposed. The core values, drivers and tools of the proposed framework were further developed based on case studies in three SMEs in the KRI.

Findings

Proposed framework is able to provide a simple pathway for SMEs to systematically implement Lean techniques in seven functional areas in order to create Lean culture in the organisation. Business performance measurement in terms of profitability, customer satisfaction, employee’s satisfaction, competitiveness growth and ergonomic improvement is presented in favour of evaluating Lean outcomes appropriately. It also presents the experience of small firms in implementing Lean programmes to show that Lean is valid in SMEs.

Research limitations/implications

The framework concentrates only on the internal issues of the organisation, while external variables such as national culture and external support are excluded.

Practical implications

The framework assists improvements in SMEs that either initially attempt to start Lean journey or those that are at more advanced levels towards excellent-Lean manufacturing. The framework can also be used as a self-assessment model to determine the degree of Lean readiness.

Originality/value

To the best knowledge of the author, it is the first framework that integrates Lean techniques with MBNQA criteria to support Lean implementation in SMEs. It is also the first study regarding Lean-excellence in the KRI.

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.

Operations flow effectiveness: a systems approach to measuring flow performance

Purpose

Effective operations management systems (OMS) measurement remains a critical issue for theorists and practising managers (Neely, 2005; Bititci et al., 2012). Traditional labor efficiency measures sufficed when all that was made could be sold or when mass production systems filled warehouses with stock and the OMS had little relationship with “the consumer.” Modern manufacturing systems require a different form of flow optimization (beyond labor efficiency) measurement (Schmenner, 2015). The essential unit of measure for all OMS designs is the optimal use of time for process value adding and the flow of materials into and from the conversion process. Timely flow, therefore, satisfies the needs of multiple organizational stakeholders including cash flow (accounting), consumer reaction times (marketing) and the general steady state flow of materials (sales and supply chain). The purpose of this paper is to present the results of testing a new performance measure of operations flow effectiveness (OFE) with ten purposively selected cases.

Design/methodology/approach

The paper is theory building using ten, purposively selected, longitudinal case studies drawn from the UK high-value manufacturing (HVM) sector using a pluralist methodology of interviews, observation and secondary data.

Findings

The OFE measure provides a holistic view of material flow through the input-process-output cycles of a firm. The measure highlights OMS design weaknesses and flow inhibitors that reduce cash flow using a time-based approach to measuring OMS performance. The study validates the OFE measure and has identified six key design elements that enable high flow performance.

Originality/value

The paper tests a new process-focused flow performance measure. The measure supports a holistic approach to the manufacturing enterprise and allows different OMS designs to be evaluated so that organizational learning may be enacted to support performance improvement.

Lean healthcare: scale, scope and sustainability

Purpose

Lean healthcare is highlighted in the literature as an approach to quality improvement and operational efficiency. The purpose of this paper is to study how Lean healthcare has been implemented by analyzing empirical outcomes.

Design/methodology/approach

The authors used a literature review as the primary research method, following the Preferred Reporting Items for Systematic Reviews and Meta-Analyses process. Peer-reviewed journals were analyzed – searching for Lean healthcare implementation, tools used, wastes addressed, outcomes and sustainability.

Findings

Evidence suggests that Lean can improve healthcare operational effectiveness. However, empirical studies show implementation is still highly localized with small successes. Most transformations are focused on implementing one or two Lean tools that primarily target patient waiting times and there is minimal evidence about sustainability. Establishing clear definitions for healthcare-related Lean terminology may improve practice, especially episodic care and service quality.

Originality/value

This work provides a Lean healthcare case review. The research makes a significant contribution to Lean healthcare by increasing understanding (scale, scope and sustainability). From a theory building perspective, the authors suggest that barriers to adoption include a common healthcare-specific Lean terminology, and a need to expand implementation beyond small successes. This understanding will help identify key areas for further research in Lean healthcare management.

Implementation of inclusive education for children with intellectual and developmental disabilities in African countries: a scoping review

Purpose: To advance understanding of practices that support inclusion of children with intellectual and developmental disabilities in inclusive education classrooms in Africa by conducting a review of the extant literature. Methods: Five academic databases were searched supplemented by a hand search of key journals and references of included studies. Two authors independently screened studies via a reference manager (Covidence) which allowed for blinding. A third author was consulted in cases of conflict. Results: Thirty articles that provided empirical evidence of inclusive education implementation were included. Eight articles highlighted practices that support inclusion of children with intellectual and developmental disabilities. Using Bronfenbrenner's bioecological framework, findings revealed that inclusive education implementation is influenced by factors on the bio level, micro level, meso level, and macro level. Recommendations for promoting inclusive education implementation are provided. Conclusions: Inclusion goes beyond teachers and requires strong commitment of other stakeholders such as families and governments. To guarantee the smooth inclusion of children with special education needs and particularly with intellectual and developmental disabilities, a set of practices validated through rigorous research as supportive and unique and that can be universal to Africa is wise. Implications for rehabilitation A number of strategies were identified that can improve the classroom inclusion of children with intellectual and developmental disabilities. Development of policies that support such strategies could improve implementation. Inclusion goes beyond teachers. Rehabilitation professionals (i.e. occupational therapists) and educational professionals should partner to identify practical solutions to the challenges of creating inclusive environments for children with special education needs. Committing more resources and time towards the development and implementation of special education policies can advance the successful inclusion of children with special education needs.

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.

A Knowledge Network and Mobilisation Framework for Lean Supply Chain Decisions in Agri-Food Industry

Making the right decisions for food supply chain is extremely important towards achieving sustainability in agricultural businesses. This paper explores that knowledge sharing to support food supply chain decisions to achieve lean performance (i.e. to reduce/eliminate non-value-adding activities, or “waste” in lean term). The focus of the paper is on defining new knowledge networks and mobilisation approaches to address the network and community nature of current supply chains. Based on critical analysis of the state-of-the-art in the topic area, a knowledge network and mobilisation framework for lean supply chain management has been developed. The framework has then been evaluated using a case study from the food supply chain. Analytic Hierarchy Process (AHP) has been used to incorporate expert's view on the defined knowledge networks and mobilisation approaches with respect to their contribution to achieving various lean performance objectives. The results from the work have a number of implications for current knowledge management and supply chain management in theory and in practice.

Lean implementation and a process approach – an exploratory study

Purpose

This paper proposes, that without acknowledging that lean adoption needs to reach beyond the shop floor, it cannot be sustained, and neither is the transformation into a truly lean enterprise possible. The purpose of this paper is to address the gap in the scientific knowledge regarding the challenges of lean adoption in manufacturing organizations. The underlying assumption is that successful and sustainable adoption of lean should be approached from the perspective of business process change (BPC). By applying the logic of BPC to manufacturing environments, and by exploring the opportunities for lean implementation that reach far beyond manufacturing, the study is expected to contribute to the development of the existing knowledge.

Design/methodology/approach

The research objectives were achieved by conducting the qualitative case study. Two case companies were chosen based on their differing approaches to the introduction and implementation of lean initiatives. Data were collected through in depth, semi-structured interviews supported by shop-floor observations.

Findings

The paper provides insights into how can lean implementation be facilitated while a systematic, BPC is utilized. By contrasting the two cases, meaningful conclusions were drawn and certain managerial implications outlined.

Originality/value

This paper presents a new approach to lean implementation and aims to bridge both the theoretical and empirical gaps between the concepts of lean implementation and business process management.

V. Lean services: a systematic review

Purpose

The purpose of this paper is to highlight the importance of Lean methodology through an exhaustive literature review, and its implications and application in the service industry right from its initiation in 1990s till date.

Design/methodology/approach

The paper summarises the evolution of Lean in services and has systematically classified the reviewed literature in four dimensions, namely time, publisher, region and content. Further under “time” dimension, the literature is classified into Pre-Lean era, Lean awareness era, Lean Exploration era and Lean implementation era. Under the “content” dimension, the categories include theoretical foundation, frameworks/models and application/case studies.

Findings

The analysis inferred; Lean is gaining roads in services, though the research is still at nascent stage. Lean is applicable in services though transfer of Lean manufacturing principles to services has certain limitations because of the characteristics of services. The need is to focus on process difference between services and manufacturing. Respect for people and employment engagement is critical to Lean in service. The authors identified the necessity to standardise the Lean service definition, principles, and tools and to develop guidelines for structured implementation in service industry.

Research limitations/implications

Though multiple databases have been taken-up but that does not assume that the literature presented in this paper is by any means comprehensive. Development of a standard model/framework for Lean services is critical for future research. Rigorous industry-specific studies, specifically in developing nations are another area for future research. Future studies could analyse the impact of join applications and possible links between Lean service and other approaches like TQM, Six Sigma, etc., with an aim of process improvement.

Practical implications

This paper would serve as a resource for Lean practitioners as well as researchers as a fundamental platform, contributing to Lean body of knowledge.

Social implications

Service industry has special significance to the society in large. Many services including governments, public interest services, non-profit organisations, healthcare, banking, consulting, etc., has a significant share across markets. Lean being a proven methodology for successful process improvements has to be looked at from a services perspective. This paper helps in such interest.

Originality/value

Publications reviewing the adoption of Lean in services is scarce in literature. This paper serves as an excellent resource for research on the subject and will facilitate academicians and practitioners to objectively understand Lean in service sector.

Lean-team effectiveness through leader values and members’ informing

Purpose

Although empirical tests of effective lean-team leadership are scarce, leaders are often blamed when lean work-floor initiatives fail. In the present study, a lean-team leader’s work values are assumed to affect his or her team members’ behaviors and, through them, to attain team effectiveness. Specifically, two of Schwartz et al.’s (2012) values clusters (i.e. self-transcendence and conservation) are hypothesized to be linked to team members’ degree of information and idea sharing and, in turn, to lean-team effectiveness. The paper aims to report the examination of these hypotheses.

Design/methodology/approach

Survey responses (n=429) of both leaders and members of 25 lean-teams in services and manufacturing organizations were aggregated, thereby curbing common-source bias. To test the six hypotheses, structural equation modeling was performed, with bootstrapping, linear regression analyses, and Sobel tests.

Findings

The positive relationship between lean-team effectiveness and leaders’ self-transcendence values, and the negative relationship between lean-team effectiveness and leaders’ conservation values were partly mediated by information sharing behavior within the team.

Research limitations/implications

Future research must compare the content of effective lean-team values and behaviors to similar non-lean teams.

Practical implications

Appoint lean-team leaders with predominantly self-transcendence rather than conservation values: to promote work-floor sharing of information and lean-team effectiveness.

Originality/value

Human factors associated with effective lean-teams were examined, thereby importing organization-behavioral insights into the operations management literature: with HRM-type implications.

The impact of a readiness program for implementing and sustaining continuous improvement processes

Purpose

The purpose of this paper is to describe a readiness programme designed to increase employees’ awareness of order and cleanliness as a way of building the necessary foundation for implementing and sustaining continuous improvement processes. In this paper, the authors propose a new readiness programme based on the principles of 5S, with the aim of strengthening employees’ motivation and involvement prior to 5S being implemented.

Design/methodology/approach

The research is based on case study methodology, followed by a programme of four structured activities. The validity of the programme is shown through the implementation of the activities in two different organizations.

Findings

The readiness programme was applied before 5S was successfully implemented. The degree of awareness and motivation of the programme participants improved as a result of these activities. Moreover, the activities increased people’s motivation to participate in improvement activities.

Originality/value

Applying a readiness programme before implementing 5S can help organizations to achieve and sustain improvement activities, thus increasing worker commitment and motivation.

Leanness assessment: a literature review

Purpose

Assessing the outcome of lean transformation journey has been of interest to both researchers and practitioners. Various qualitative and quantitative assessment methodologies have been proposed in literature to track and measure the degree of leanness attained. The purpose of this paper is to understand the evolution of this leanness assessment literature over different attributes and identify gaps for future research.

Design/methodology/approach

A detailed literature review of peer-reviewed journal articles and conference papers addressing leanness assessment was performed. Content analysis methodology involving a four-step process suggested by Mayring (2004) was adopted for this study.

Findings

The number of studies in literature on leanness assessment is low when compared to that in the area of lean implementation. Assessment methodologies developed are of wide range, varying from simple qualitative checklist to complex quantitative mathematical models. Following the trend of lean implementation literature, lean thinking assessment literature is also getting transformed from process-level monitoring to enterprise-level monitoring. Finally, based on this review, a simplified leanness assessment framework is proposed for future validation.

Research limitations/implications

Only peer-reviewed journals and conference papers were analyzed, while excluding the manuals, reports, and white papers from practice. Clustering of leanness assessment literature revealed that future studies in this domain would fall into two major categories, namely manufacturing leanness assessment and service leanness assessment.

Practical implications

Practitioners can use this review study to choose a suitable methodology for assessing the leanness attained in their organization by controlling for the structural attributes identified.

Originality/value

This is the first paper to review the topic “leanness assessment.” The review analyzes the entire literature available on leanness assessment to summarize its current status and identify potential future directions.

Supply chain processes

Purpose

– The purpose of this paper is to examine the value chain processes that represent the “black box” between supply logistics integration and competitive operational performance in firms. To realize this objective, the authors develop a research model which comprises a series of linkages from supply logistics integration to operational outcomes using Porter’s concept of value chain and the relational view of resource-based theory as theoretical lenses.

Design/methodology/approach

– The data set for testing the hypothesized relationships in this study was drawn from 232 Australian manufacturing firms.

Findings

– The findings show that there is no significant direct relationship between supply logistics integration and competitive operational performance; rather, the relationship is fully mediated by inbound supply performance and internal lean production processes. Further, lean production processes have a positive effect on inbound supply performance.

Research limitations/implications

– The study shows the importance of managing both internal (production processes) and external processes (logistics and supply chain) of firms’ operations in an integrated manner in which supply logistics integration act through key internal processes to impact competitive performance which the end customers actually experience.

Originality/value

– This is the first study which uncovers what happens “in between” the incoming materials and the end outputs delivered by firms into the market. This “in between black box” is important in improving our understanding of how inbound supply activities are translated into outbound competitive performance outcomes.

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

Purpose

– The purpose of this paper is to suggest a solution to the problem of implementing a full “Lean” methodology for small-/medium-sized enterprises (SMEs) in a developing economy.

Design/methodology/approach

– This is a reflective paper that looks at an illustrative case study against the wider perspectives of the financial and resource costs of implementing a full lean programme in a developing country and suggests that using a “Lean Lite” approach may help the consultant/manager introduce lean concepts into a manufacturing organisation in a developing country.

Findings

– The paper concludes that “Lean Lite” as an approach that can be used to introduce lean initiatives in an SME in a developing economy by allowing a company with very limited resources to engage not only in business improvement but also in improving working conditions and education for employees.

Research limitations/implications

– The observations are limited to a single case study, although tempered by the authors’ wider experience. Further empirical research and critique of the original research is required to validate the observations and conclusions.

Practical implications

– The proposed “Lean Lite” initiative can help to introduce lean concepts to an organisation with limited financial and other resources. This helps organisations to increase productivity and assists the adoption of the lean philosophy and principles in a developing economy. The approach may also be used to engage in a wider corporate social responsibility strategy at ground level.

Social implications

– The social benefits as a result of implementing a Lean Lite approach include improving working conditions and educating employees.

Originality/value

– The paper proposes an approach that can be used to widen organisational involvement in lean initiatives in a developing economy by allowing a company with limited resources to engage not only in business improvement but also in improving working conditions and education for employees. As such the approach has both economic and social benefits.

How did the publication of the book The Machine That Changed The World change management thinking? Exploring 25 years of lean literature

Purpose

– The purpose of this paper is to take a critical, analytical approach to explore the growth and spread of Lean through the academic and practitioner community over the last 25 years to understand the impact of the book The Machine that Changed the World on management thinking.

Design/methodology/approach

– A comprehensive and systematic review of the extant literature of lean was undertaken and analysed critically to observe patterns and trends that could explain the acceptance of Lean as an operations management philosophy. The review spans from 1987 to 2013. To enable us to effectively manage and understand the diffusion of this literature a database, the Lean Publications Database, was constructed. The number of publications has been adjusted to compensate for growth in the total number of articles published in the same period.

Findings

– Lean has evolved to be one of the best-known, yet fiercely debated, process improvement methodologies. It emerged during a proliferation of such methodologies in the business and management literature. Lean has developed from a generic description of Toyota Production System (TPS) to a particular type of organisational and management intervention focused on best practice and process improvement methodologies.

Research limitations/implications

– This paper provides the first comprehensive review of the Lean literature, from the perspective of Lean as the unit of analysis. It covers both sides of the academic debate and categorises the progression of Lean from its origins as a generic description of TPS to a movement that has changed management systems in many and diverse sectors.

Practical implications

– This paper demonstrates how Lean research, application and thinking has evolved over 25 years from its origins in Japanese auto-manufacturing to a holistic value system that is applicable to all business sectors, both private and public.

Originality/value

– In most empirical studies on Lean, the unit of analysis is the organisation. In this study, the unit of analysis is the Lean phenomenon itself. This paper examines the impact of The Machine that Changed the World on management thinking. In addition, it presents a step to developing an underpinning theory by linking Lean to the Theory of Swift, Even Flow. As such it is of interest to academics in the field of operations management and offers a contribution to knowledge. It is also likely to be of interest to policy makers. Considerable amounts of public money have been spent, and continue to be spent, on promoting Lean. Taxpayers and policymakers are likely to be interested in whether that expenditure is justifiable. 25 years of publications have been analysed to provide clarity around this popular approach to organisational improvement.