Implementing lean—Outcomes from SME case studies

Abstract The purpose of this work was to identify critical success factors for lean implementation. It followed two first-time implementations of lean in small to medium-sized enterprises (SMEs). The case studies collectively spanned over four years. It was observed that the real problem with achieving lean success was not management commitment but their ignorance of what they should commit to, hence a knowledge problem. This paper provides new insights into the role of knowledge as a causal factor in the successful implementation of lean and especially in organisations with limited resources. For practitioners, management knowledge needs active consideration in the implementation phase. Management knowledge is particularly significant in SME implementations due to their resource constraints. Researchers still need to define the success factors more explicitly, including the specific management commitments.

[1]  Peter Hines How to create and sustain a lean culture , 2010 .

[2]  S. Deshmukh,et al.  Strategy development by SMEs for competitiveness: a review , 2008 .

[3]  Flávio Sanson Fogliatto,et al.  Assessment of Organizational Maturity for Lean Change , 2013 .

[4]  Peter T. Ward,et al.  Lean manufacturing: context, practice bundles, and performance , 2003 .

[5]  Rambabu Kodali,et al.  A critical review of lean supply chain management frameworks: proposed framework , 2015 .

[6]  Sanjay Bhasin,et al.  An appropriate change strategy for lean success , 2012 .

[7]  Ben J. Hicks,et al.  Lean information management: Understanding and eliminating waste , 2007, Int. J. Inf. Manag..

[8]  J. Kotter Leading change: why transformation efforts fail , 2009, IEEE Engineering Management Review.

[9]  Deborah J. Nightingale,et al.  Development of a Lean Enterprise Transformation Maturity Model , 2002, Inf. Knowl. Syst. Manag..

[10]  Pius Achanga,et al.  Critical success factors for lean implementation within SMEs , 2006 .

[11]  Rambabu Kodali,et al.  A literature review of empirical research methodology in lean manufacturing , 2014 .

[12]  Francis J. Yammarino,et al.  Organizational change: A categorization scheme and response model with readiness factors , 2003 .

[13]  Linda S. Ackerman-Anderson,et al.  Beyond change management : advanced strategies for today's transformational leaders , 2001 .

[14]  Richard Cooney,et al.  Is “lean” a universal production system?: Batch production in the automotive industry , 2002 .

[15]  Daniel T. Jones,et al.  The machine that changed the world : based on the Massachusetts Institute of Technology 5-million dollar 5-year study on the future of the automobile , 1990 .

[16]  M. L. Emiliani,et al.  Leaders lost in transformation , 2005 .

[17]  Maurizio Zollo,et al.  Deliberate Learning and the Evolution of Dynamic Capabilities , 2002 .

[18]  J. P. Womack Moving beyond the tool age [lean management] , 2007 .

[19]  V. Cruz-Machado,et al.  Sustainable Lean Implementation: An Assessment Tool , 2015 .

[20]  Cory R. A. Hallam,et al.  Analysis of the Toyota Production System and the genesis of Six Sigma programs: An imperative for understanding failures in technology management culture transformation in traditional manufacturing companies , 2010, PICMET 2010 TECHNOLOGY MANAGEMENT FOR GLOBAL ECONOMIC GROWTH.

[21]  J. Kennedy Leadership and culture in New Zealand , 2000 .

[22]  Matthias Holweg,et al.  The genealogy of lean production , 2007 .

[23]  C. Argyris Double Loop Learning in Organizations , 1996 .

[24]  D. Pons,et al.  Defining Lean Change—Framing Lean Implementation in Organizational Development , 2017 .

[25]  J. Worley,et al.  The role of communication and management support in a lean manufacturing implementation , 2006 .

[26]  Francisco Loforte Ribeiro,et al.  Exploring agile methods in construction small and medium enterprises: a case study , 2010, J. Enterp. Inf. Manag..

[27]  Pauline Found,et al.  Staying lean: thriving, not just surviving , 2008 .

[28]  R. Grant,et al.  Environments: Organizational Capability as Knowledge Integration , 2022 .

[29]  J. Klein,et al.  The human costs of manufacturing reform , 1989 .

[30]  James P. Womack,et al.  Lean Thinking: Banish Waste and Create Wealth in Your Corporation , 1996 .

[31]  B. Flyvbjerg Five Misunderstandings About Case-Study Research , 2006, 1304.1186.

[32]  Dirk J. Pons,et al.  Implementing Lean Practices: Managing the Transformation Risks , 2013 .

[33]  Rose A.M.N.,et al.  LEAN MANUFACTURING BEST PRACTICES IN SMES , 2011 .

[34]  A. Graves,et al.  Implementing Lean in aerospace-challenging the assumptions and understanding the challenges , 2003 .

[35]  Maike Scherrer-Rathje,et al.  Learning to be lean : the influence of external information sources in lean improvements , 2011 .

[36]  J. Burgoyne,et al.  Towards the Learning Company , 1989 .

[37]  Mohamed Mohamed Naim,et al.  A theoretical framework for economic sustainability of manufacturing , 2006 .

[38]  J. Barney Firm Resources and Sustained Competitive Advantage , 1991 .

[39]  Qing Hu,et al.  Lean implementation within SMEs: a literature review , 2015 .

[40]  S. Afshin Mansouri,et al.  The lean-performance relationship in services: a theoretical model , 2014 .

[41]  Frank Wiengarten,et al.  Internal lean practices and operational performance: The contingency perspective of industry clockspeed , 2013 .

[42]  Taiichi Ohno,et al.  Toyota Production System : Beyond Large-Scale Production , 1988 .

[43]  Claire McInerney,et al.  Knowledge management and the dynamic nature of knowledge , 2002, J. Assoc. Inf. Sci. Technol..

[44]  Jeff Cox,et al.  The Goal: A Process of Ongoing Improvement , 1984 .

[45]  Gerhard Plenert What Is Lean , 2007 .

[46]  Russell L. Ackoff,et al.  On misdirecting management , 2002 .

[47]  P. Senge The fifth discipline : the art and practice of the learning organization/ Peter M. Senge , 1991 .

[48]  R. Delbridge Life on the line in contemporary manufacturing , 1998 .

[49]  Kevin McCormack,et al.  The development of a supply chain management process maturity model using the concepts of business process orientation , 2004 .

[50]  Leonardo Rivera,et al.  Measuring the impact of Lean tools on the cost-time investment of a product using cost-time profiles , 2007 .

[51]  Nicola Bateman,et al.  Wider applications for Lean: An examination of the fundamental principles within public sector organisations , 2014 .

[52]  Tingting Yan,et al.  The moderation of lean manufacturing effectiveness by dimensions of national culture: Testing practice-culture congruence hypotheses , 2014 .

[53]  Kim Hua Tan,et al.  Green and lean sustainable development path in China: Guanxi, practices and performance , 2018 .

[54]  Dooyoung Shin,et al.  Critical Implementation Issues in Total Quality Management , 1998 .

[55]  J. Kotter,et al.  The Heart of Change: Real-Life Stories of How People Change Their Organizations , 2002 .

[56]  Manoj Kumar Tiwari,et al.  Implementing the Lean Sigma framework in an Indian SME: a case study , 2006 .

[57]  Bin Zhou,et al.  Lean principles, practices, and impacts: a study on small and medium-sized enterprises (SMEs) , 2016, Ann. Oper. Res..

[58]  Anna Kosieradzka,et al.  Maturity Model for Production Management , 2017 .

[59]  Eric W. K. Tsang Organizational Learning and the Learning Organization: A Dichotomy Between Descriptive and Prescriptive Research , 1997 .

[60]  Rambabu Kodali,et al.  Lean production: literature review and trends , 2015 .

[61]  Michael Rosemann,et al.  The Six Core Elements of Business Process Management , 2015 .

[62]  Annabeth L. Propst,et al.  The New Economics: For Industry, Government, Education , 1996 .

[63]  Andrew Thomas,et al.  Applying lean six sigma in a small engineering company – a model for change , 2008 .

[64]  C. Prahalad,et al.  Competing for the Future , 1994 .

[65]  Vaibhav Gupta,et al.  Application of value stream mapping for lean operations and cycle time reduction: an Indian case study , 2005 .

[66]  P. Hines,et al.  Learning to evolve: A review of contemporary lean thinking , 2004 .

[67]  Garry Pairaudeau,et al.  Creativity, innovation and lean sigma: a controversial combination? , 2011, Drug discovery today.

[68]  Christopher G. Worley,et al.  Organisation Development and Change , 2007 .

[69]  Paul Stewart,et al.  The Nissan Enigma: Flexibility at Work in a Local Economy , 1992 .

[70]  Maike Scherrer-Rathje,et al.  An empirical examination of the best practices to ensure manufacturing flexibility: Lean alignment , 2009 .

[71]  B. Burnes Complexity Theories and Organizational Change , 2005 .

[72]  G. Thomas A Typology for the Case Study in Social Science Following a Review of Definition, Discourse, and Structure , 2011 .

[73]  Stefan Schmidt From Hype to Ignorance – A Review of 30 Years of Lean Production , 2011 .

[74]  S. Bhasin Improving performance through Lean , 2011 .

[75]  J. Liker The Toyota Way , 2003 .

[76]  Maneesh Kumar,et al.  Determinants and barriers to lean implementation in food-processing SMEs – a multiple case analysis , 2016 .

[77]  新郷 重夫,et al.  A study of the Toyota production system from an industrial engineering viewpoint , 1989 .

[78]  James K. Franz,et al.  The Toyota Way to Continuous Improvement: Linking Strategy and Operational Excellence to Achieve Superior Performance , 2011 .

[79]  Shaul Oreg,et al.  Change Recipients’ Reactions to Organizational Change , 2011 .

[80]  K. Lewin Frontiers in Group Dynamics , 1947 .

[81]  A. Adcroft,et al.  Against lean production , 1992 .

[82]  Emily Adams,et al.  Real Numbers: Management Accounting in a Lean Organization , 2003 .

[83]  Ilias Vlachos,et al.  Applying lean thinking in the food supply chains: a case study , 2015 .

[84]  Christopher A. Voss,et al.  Contingency research in operations management practices , 2008 .

[85]  Zoe Radnor,et al.  Lean in UK Government: internal efficiency or customer service? , 2013 .

[86]  M. L. Emiliani,et al.  Origins of lean management in America: The role of Connecticut businesses , 2006 .

[87]  Peter Hines,et al.  New Development: Creating a Lean University , 2007 .