The aim of this research is to determine the current and desired level of lean maturity level in the local manufacturing industries of Pakistan. This can certainly assist the local industry of Pakistan to optimize their processes, shrink wastes and increase the productivity by using this method. The developed lean assessment model evaluates the lean manufacturing and measures the leanness of the industries in terms of lean maturity model. It comprises of three categories. The assessment model consists of twelve factors on which the lean manufacturing is assessed which include leadership, communication, trainings, inventory, quality, continuous improvement, production processes, lean tools, maintenance, cost, on-time-delivery and energy-efficiency. A series of stages involved in developing lean assessment model, named as modified LESAT, are subdivided into four main phases: detailed literature review, development of lean assessment, data analysis and AS-IS and TO-BE analysis with gap identification. Current maturity level of the industries of Pakistan comes out to be 3.00, that managers and all the staff have knowledge about lean. The future state comes out to 4.00 that lean will be implemented to a greater extent and industry is striving to achieve more via continuous improvement. The gaps identified in many industries are weak in terms of energy efficient, inventory, quality, training, production processes and lean tools. The Pakistani industries must work and improve in view of factors identified. This will aid in achieving more productivity, better performance and excellent quality to survive in the market.
lean manufacturing, maturity levels, lean assessment, self-assessment tool, lean perspectives and factors
Muhammad Usman. Corresponding author. Research Scholar, Department of Engineering Management, University of Engineering and Technology, Taxila
Wasim Ahmad. Professor, Department of Engineering Management, University of Engineering and Technology, Taxila
Akram, M. A. A. R. (2013). Measuring The Leanness Of Manufacturing Systems By Using Fuzzy Topsis: A Case Study Of The ‘Parizan Sanat’ Company. South African Journal of Industrial Engineering, 24(3), 8.
Behrouzi, F., & Wong, K. Y. (2011). Lean performance evaluation of manufacturing systems: A dynamic and innovative approach. Procedia Computer Science, 3, 388-395. doi:https://doi.org/10.1016/j.procs.2010.12.065
Bento, G., & Tontini, G. (2018). Developing an instrument to measure lean manufacturing maturity and its relationship with operational performance. Total Quality Management & Business Excellence, 29, 1-19. doi:10.1080/14783363.2018.1486537
Bhasin, S. (2011). Measuring the Leanness of an organisation. International Journal of Lean Six Sigma, 2(1), 55-74. doi:10.1108/20401461111119459
Büyüközkan, G., Kayakutlu, G., & Karakadılar, İ. S. (2015). Assessment of lean manufacturing effect on business performance using Bayesian Belief Networks. Expert Systems with Applications, 42(19), 6539-6551. doi:https://doi.org/10.1016/j.eswa.2015.04.016
Chen, C.-C. (2008). An objective-oriented and product-line-based manufacturing performance measurement. International Journal of Production Economics, 112(1), 380-390. doi:10.1016/j.ijpe.2007.03.016
Cherrafi, A., Elfezazi, S., Chiarini, A., Mokhlis, A., & Benhida, K. (2016). The integration of lean manufacturing, Six Sigma and sustainability: A literature review and future research directions for developing a specific model. Journal of Cleaner Production, 139, 828-846. doi:https://doi.org/10.1016/j.jclepro.2016.08.101
Doolen, T. L., & Hacker, M. E. (2005). A review of lean assessment in organizations: An exploratory study of lean practices by electronics manufacturers. Journal of Manufacturing Systems, 24(1), 55-67. doi:https://doi.org/10.1016/S0278-6125(05)80007-X
Dora, M., Kumar, M., Van Goubergen, D., Molnar, A., & Gellynck, X. (2013). Operational performance and critical success factors of lean manufacturing in European food processing SMEs. Trends in Food Science & Technology, 31(2), 156-164. doi:10.1016/j.tifs.2013.03.002
Dubey, R., & Singh, T. (2015). Understanding complex relationship among JIT, lean behaviour, TQM and their antecedents using interpretive structural modelling and fuzzy MICMAC analysis. The TQM Journal, 27, 42-62. doi:10.1108/TQM-09-2013-0108
E.Mar, Y., Lovena, N., Krisen, P., Vianee, B., & Girish, J. (2012). Non-Parametric Tests.
Eniola, A. A., Olorunleke, G. K., Akintimehin, O. O., Ojeka, J. D., & Oyetunji, B. (2019). The impact of organizational culture on total quality management in SMEs in Nigeria. Heliyon, 5(8), e02293. doi:https://doi.org/10.1016/j.heliyon.2019.e02293
Farias, L. M. S., Santos, L. C., Gohr, C. F., Oliveira, L. C. d., & Amorim, M. H. d. S. (2019). Criteria and practices for lean and green performance assessment: Systematic review and conceptual framework. Journal of Cleaner Production, 218, 746-762. doi:https://doi.org/10.1016/j.jclepro.2019.02.042
Galankashi, M. R., Helmi, S. A., Hisjam, M., & Rahim, A. J. I. J. o. V. C. M. (2018). Leanness assessment in automotive industry: case study approach. 9, 70.
Galeazzo, A. (2021). Degree of leanness and lean maturity: exploring the effects on financial performance. Total Quality Management & Business Excellence, 32(7-8), 758-776. doi:10.1080/14783363.2019.1634469
Ghasemi, A., & Zahediasl, S. (2012). Normality Tests for Statistical Analysis: A Guide for Non-Statisticians. International journal of endocrinology and metabolism, 10, 486-489. doi:10.5812/ijem.3505
Gonçalves, M. T., & Salonitis, K. (2017). Lean Assessment Tool for Workstation Design of Assembly Lines. Procedia CIRP, 60, 386-391. doi:10.1016/j.procir.2017.02.002
Gupta, S., & Jain, S. K. (2013). A literature review of lean manufacturing. International Journal of Management Science and Engineering Management, 8(4), 241-249. doi:10.1080/17509653.2013.825074
Harpe, S. E. (2015). How to analyze Likert and other rating scale data. Currents in Pharmacy Teaching and Learning, 7(6), 836-850. doi:https://doi.org/10.1016/j.cptl.2015.08.001
Harry N. Boone, D. A. B. (2012). Analyzing likert data. Journal of Extension, 50(2).
Hartford. (2020, 19/10/2017). 35 Lean Manufacturing Tools: The Ultimate List. Retrieved from http://resources.hartfordtechnologies.com/
Hartini, S., Ciptomulyono, U., Anityasari, M., & Sriyanto. (2020). Manufacturing sustainability assessment using a lean manufacturing tool. International Journal of Lean Six Sigma, 11(5), 943-971. doi:10.1108/IJLSS-12-2017-0150
Helleno, A. L., de Moraes, A. J. I., & Simon, A. T. (2017). Integrating sustainability indicators and Lean Manufacturing to assess manufacturing processes: Application case studies in Brazilian industry. Journal of Cleaner Production, 153, 405-416. doi:10.1016/j.jclepro.2016.12.072
Hopkins, K. D., & Weeks, D. L. (1990). Tests for Normality and Measures of Skewness and Kurtosis: Their Place in Research Reporting. Educational and Psychological Measurement, 50(4), 717-729. doi:10.1177/0013164490504001
Johanna, Z., Johan, Z. J., Ibrahim, I., Ahmad Jamil, N., Mohd, S., & Amer, A. (2019). Lean Production Determinant Factors in Malaysia Paper Manufacturer Industry. International Journal of Supply Chain Management, 8.
Karvonen, T., Rodriguez, P., Kuvaja, P., Mikkonen, K., & Oivo, M. (2012, 5-8 Sept. 2012). Adapting the Lean Enterprise Self-Assessment Tool for the Software Development Domain. Paper presented at the 2012 38th Euromicro Conference on Software Engineering and Advanced Applications.
Kiran, D. R. (2020). Chapter 11 – Kaizen and continuous improvement. In D. R. Kiran (Ed.), Work Organization and Methods Engineering for Productivity (pp. 155-161): Butterworth-Heinemann.
Knol, W. H., Slomp, J., Schouteten, R. L. J., & Lauche, K. (2018). Implementing lean practices in manufacturing SMEs: testing ‘critical success factors’ using Necessary Condition Analysis. International Journal of Production Research, 56(11), 3955-3973. doi:10.1080/00207543.2017.1419583
Kovács, T., Kő, A., & Demeter, K. (2020). Measuring the impact of lean practices on manufacturing performance – case study from the process industry. International Journal of Lean Six Sigma, 11(6), 1193-1218. doi:10.1108/IJLSS-01-2019-0004
Laoha, C., & Sukto, S. (2015). Lean assessment for manufacturing of small and medium enterprises (SMEs): A case study of electronics industry in the Northeast of Thailand. KKU Engineering Journal, 42. doi:10.14456/kkuenj.2015.28
Losonci, D., Demeter, K., & Jenei, I. (2011). Factors influencing employee perceptions in lean transformations. International Journal of Production Economics, 131, 30-43. doi:10.1016/j.ijpe.2010.12.022
Lucas Gabriel Zanon, T. F. U. K. F. E. (2020). Performance measurement and lean maturity: congruence for improvement. Production Planning & Control, The Management of Operations, 15. doi:10.1080/09537287.2020.1762136
Maasouman, M. A., & Demirli, K. (2015). Assessment of Lean Maturity Level in Manufacturing Cells. IFAC-PapersOnLine, 48(3), 1876-1881. doi:https://doi.org/10.1016/j.ifacol.2015.06.360
Mostafa, S., Dumrak, J., & Soltan, H. (2013). A framework for lean manufacturing implementation. Production & Manufacturing Research, 1(1), 44-64. doi:10.1080/21693277.2013.862159
Mourtzis, D., Papathanasiou, P., & Fotia, S. (2016). Lean Rules Identification and Classification for Manufacturing Industry. Procedia CIRP, 50, 198-203. doi:10.1016/j.procir.2016.04.097
Norani Nordin, B. M. D., Dzuraidah Abdul Wahab and Mohd Nizam Ab. Rahman. (2012). A framework for organisational change management in lean manufacturing implementation. Int. J. Services and Operations Management, 12(1), 17.
Nordin, N., Osman, A., & Adom, A. (2016). A Review on Lean Assessment Models and Performance Measures. Journal of Advanced Review on Scientific Research, 21, 2289-7887.
Oleghe, O., & Salonitis, K. (2018). Leanness Assessment Tools and Frameworks. In J. P. Davim (Ed.), Progress in Lean Manufacturing (pp. 1-37). Cham: Springer International Publishing.
Omogbai, O., & Salonitis, K. (2016). A Lean Assessment Tool Based on Systems Dynamics. Procedia CIRP, 50, 106-111. doi:https://doi.org/10.1016/j.procir.2016.04.169
Pius Achanga, E. S., Rajkumar Roy and Geoff Nelder. (2005). Critical success factors for lean implementation within SMEs. Journal of Manufacturing Technology Management, 17(4), 11. doi:10.1108/17410380610662889
Powell, D. J. (2018). Kanban for Lean Production in High Mix, Low Volume Environments. IFAC-PapersOnLine, 51(11), 140-143. doi:https://doi.org/10.1016/j.ifacol.2018.08.248
<PRD_LESAT_2_Tool.pdf>.
Rauch, E., Unterhofer, M., Rojas, R. A., Gualtieri, L., Woschank, M., & Matt, D. T. (2020). A Maturity Level-Based Assessment Tool to Enhance the Implementation of Industry 4.0 in Small and Medium-Sized Enterprises. 12(9), 3559.
Santos Bento, G. d., & Tontini, G. (2018). Developing an instrument to measure lean manufacturing maturity and its relationship with operational performance. Total Quality Management & Business Excellence, 29(9-10), 977-995. doi:10.1080/14783363.2018.1486537
Setianto, P., & Haddud, A. (2016). A maturity assessment of lean development practices in manufacturing industry. International journal of Advanced Operations Management, 8, 294-322. doi:10.1504/IJAOM.2016.084150
Silvério, L., Trabasso, L. G., & Pessôa, M. V. P. (2020). Performance Measurement and Improvement of Lean Manufacturing Operations: A Leanness Assessment Literature Review for the Product Development Industry. IOP Conference Series: Materials Science and Engineering, 859, 012017. doi:10.1088/1757-899x/859/1/012017
Singh, S., & Kumar, K. (2019). Review of literature of lean construction and lean tools using systematic literature review technique (2008–2018). Ain Shams Engineering Journal. doi:https://doi.org/10.1016/j.asej.2019.08.012
Stone, K. B. (2012). Lean Transformation: Organizational Performance Factors that Influence Firms’ Leanness. Journal of Enterprise Transformation, 2(4), 20. doi:10.1080/19488289.2012.664611
Tortorella, G. L., Vergara, L. G. L., & Ferreira, E. P. (2017). Lean manufacturing implementation: an assessment method with regards to socio-technical and ergonomics practices adoption. The International Journal of Advanced Manufacturing Technology, 89(9), 3407-3418. doi:10.1007/s00170-016-9227-7
Urban, W. (2015). The Lean Management Maturity Self-assessment Tool Based on Organizational Culture Diagnosis. Procedia – Social and Behavioral Sciences, 213, 728-733. doi:10.1016/j.sbspro.2015.11.527
Verrier, B., Rose, B., & Caillaud, E. (2016). Lean and Green strategy: the Lean and Green House and maturity deployment model. Journal of Cleaner Production, 116, 150-156. doi:https://doi.org/10.1016/j.jclepro.2015.12.022
Vinodh, S., & Balaji, S. R. (2011). Fuzzy logic based leanness assessment and its decision support system. International Journal of Production Research, 49(13), 4027-4041. doi:10.1080/00207543.2010.492408
Wan, H.-d., & Frank Chen, F. (2008). A leanness measure of manufacturing systems for quantifying impacts of lean initiatives. International Journal of Production Research, 46(23), 6567-6584. doi:10.1080/00207540802230058
Womack, J. P., Jones, D. T., & Roos, D. (2007). The Machine That Changed the World: The Story of Lean Production– Toyota’s Secret Weapon in the Global Car Wars That Is Now Revolutionizing World Industry: Free Press.
Wong, W. P., Ignatius, J., & Soh, K. L. (2014). What is the leanness level of your organisation in lean transformation implementation? An integrated lean index using ANP approach. Production Planning & Control, 25(4), 273-287. doi:10.1080/09537287.2012.674308
Cite this article:
Muhammad Usman & Wasim Ahmad (2021). Mapping transformational lean maturity model for discrete part industries. International Journal of Academe and Industry Research, 2(3), 1-28. https://doi.org/10.53378/348481
License:
This work is licensed under a Creative Commons Attribution (CC BY 4.0) International License.
