Lean Manufacturing Practices Assessment Case Study of Automotive Company

• Autorzy: Hąbek Patrycja , Lavios Juan J , Grzywa Adam

Identyfikatory

DOI

10.30657/pea.2023.29.36

• Języki publikacji: EN

Abstrakty

EN

Lean Manufacturing (LM) practices have gained popularity as a means to achieve high-quality products while reducing costs and delivery times. However, the implementation of LM can be challenging, with a high failure rate. This paper aims to explore the perspectives of employees and managers on LM practices implemented in an automotive company. The research involved primary and secondary data analysis, combining observation, interviews, and a questionnaire survey. The survey assessed knowledge and skills, impact on quality improvement, motivation, supervisor support, control, and engagement in LM development. The results highlight the importance of management commitment and support in achieving successful LM implementation. Moreover, the study emphasises the positive impact of LM practices on employee motivation and the overall quality of processes and products. The PDCA cycle emerged as the most impactful tool, along with other recognised tools like Poka Yoke, Andon, Kaizen, Visual Management, and the 5S method. The findings contribute to understanding the implementation and effects of LM practices, providing insights for companies seeking improvement through Lean Manufacturing methodologies.

Słowa kluczowe

EN

lean methods; lean tools; lean implementation; employees; managers; viewpoint; automotive

PL

zarządzanie szczupłe; narzędzia zarządzania; wdrożenia; pracownicy; menadżer; przemysł motoryzacyjny

• Wydawca: Oficyna Wydawnicza Stowarzyszenia Menedżerów Jakości i Produkcji
• Czasopismo: Production Engineering Archives
• Rocznik: 2023
• Tom: Vol. 29, Iss. 3
• Strony: 311--318
• Opis fizyczny: Bibliogr. 30 poz., rys.

Twórcy

autor

Hąbek Patrycja

• Faculty of Organization and Management, Silesian University of Technology, Roosevelt street 26-28, 41-800 Zabrze, Poland

autor

Lavios Juan J

• Escuela Politecnica Superior, Universidad de Burgos, Av. Cantabria s/n, 09005 Burgos, Spain

autor

Grzywa Adam

• Faculty of Organization and Management, Silesian University of Technology, Roosevelt street 26-28, 41-800 Zabrze

Bibliografia

• 1. Aadithya, B.G., Asokan, P., Vinodh, S., 2023. Lean manufacturing in fabrication industry: literature review and framework proposal. International Journal of Quality & Reliability Management, 40(6), 1485-1517. DOI: 10.1108/IJQRM-03-2021-0084
• 2. Achanga, P., Shehab, E., Roy, R., Nelder, G., 2006. Critical success factors for lean implementation within SMEs. Journal of Manufacturing Technology Management, 17(4). DOI: 10.1108/17410380610662889
• 3. Almanei, M., Salonitis, K., Xu, Y., 2017. Lean Implementation Frameworks: The Challenges for SMEs. Procedia CIRP, 63. DOI:10.1016/j.procir. 2017.03.170
• 4. Aripin, N., Nawanir, G., Mahmud, F., Fauzi, M. ,Hussain, S., Lee, K., 2023. Systematic Literature Review: Theory Perspective in Lean Manufacturing Performance. Management Systems in Production Engineering, 31(2), 230-241. DOI:10.2478/mspe-2023-0025
• 5. Bouazza,Y.,Lajjam, A., Dkhissi, B., 2021.The Impact of Lean Manufacturing on Enviromental Performance in Moroccan Automotive Industry. Management Systems in Production Engineering, 29(3) 184-192. DOI:10.2478/mspe-2021-0023
• 6. Elkhairi, A., Fedouaki, F., El Alami, S., 2019. Barriers and critical success factors for implementing lean manufacturing in SMEs. IFAC-Papers OnLine, 52(13). DOI:10.1016/j.ifacol.2019.11.303
• 7. Hamrol, A., 2016. Strategie i praktyki sprawnego działania: lean, six sigma i inne. PWN, Warszawa
• 8. Hines, P., Holwe, M., Rich, N., 2004. Learning to evolve: A review of con-temporary lean thinking. In International Journal of Operations and Production Management (Vol. 24, Issue 10). DOI:10.1108/01443570 410558049
• 9. Holweg, M., 2007. The genealogy of lean production. Journal of Operations Management, 25(2). DOI:10.1016/j.jom.2006.04.001
• 10. Ingaldi, M., Jagusiak-Kocik, M., 2014. Lean Tool used in the Automotive Industry. Production Engineering Archives. 4/3. 7-10. 10.30657/pea. 2014.04.02.
• 11. Jadhav, J. R., Mantha, S. S., Rane, S. B., 2014. Exploring barriers in lean implementation. International Journal of Lean Six Sigma, 5(2). DOI:10.1108/IJLSS-12-2012-0014
• 12. Kaneku-Orbegozo, J., Martinez-Palomino, J., Sotelo-Raffo, F., Ramos, E., 2019. Applying Lean Manufacturing Principles to reduce waste and improve process in a manufacturer: A research study in Peru. IOP Conference Series: Materials Science and Engineering. 689. 012020. 10.1088/1757-899X/689/1/012020.
• 13. Kim, Y.-H., Kwon, H., Lee, J., Chiu, C.Y., 2016. Why Do People Overestimate or Underestimate Their Abilities? A Cross-Culturally Valid Model of Cognitive and Motivational Processes in Self-Assessment Biases. Journal of Cross-Cultural Psychology, 47(9), 1201-1216. DOI:10.1177/0022022116661243
• 14. Lodgaard, E., Ingvaldsen, J. A., Gamme, I., Aschehoug, S., 2016. Barriers to Lean Implementation: Perceptions of Top Managers, Middle Managers and Workers. Procedia CIRP, 57. DOI:10.1016/j.procir.2016.11.103
• 15. Logu, P., Arun Boopathi, M, Aravinth, R., Ganesh Kumar, S., 2021. Implementation of Lean Manufacturing in Automotive Industries. International Journal of Engineering Research & Technology (IJERT) ETEDM, 9(10), 68-73
• 16. Maware, C., Parsley, D.M., 2022. The Challenges of Lean Transformation and Implementation in the Manufacturing Sector. Sustainability 14, 6287. DOI:10.3390/su14106287
• 17. Nallusamy, Dr, Adil, M.A., 2017. Implementation of Lean Tools in an Automotive Industry for Productivity Enhancement - A Case Study. International Journal of Engineering Research in Africa. 29. 175-185. 10.4028/www.scientific.net/JERA.29.175.
• 18. Oliveira, J. & Sá, José, Fernandes, A., 2017. Continuous improvement through "Lean Tools": An application in a mechanical company. Procedia Manufacturing. 13. 1082-1089. 10.1016/j.promfg.2017.09.139.
• 19. Pech, M., Vaněček, D., 2018. Methods of Lean Production to Improve Quality in Manufacturing. Quality Innovation Prosperity. 22. 01. 10.12776/qip.v22i2.1096.
• 20. Produção, G., Castro, F., Figueiredo, P., Pereira-Guizzo, C., Passos, F., 2019. Effect of the motivational factor on lean manufacturing performance: the case of a multinational consumer goods company. Gestão & Produção. 26. 10.1590/0104-530x4850-19.
• 21. Rymaszewska, A. D., 2014. The challenges of lean manufacturing implementation in SMEs. Benchmarking, 21(6). DOI: 10.1108/BIJ-10-2012-0065
• 22. Samuel, D., Found, P., Williams, S. J., 2015. How did the publication of the book The Machine That Changed The World change management thinking? Exploring 25 years of lean literature. In International Journal of Operations and Production Management, 35(10). DOI: 10.1108/IJOPM-12-2013-0555
• 23. Sankowska, A., Rygowska-Zielińska, M., 2014. The Framework of Leader’s Skills in Lean Manufacturing in the Chinese Automotive Industry - Empirical Results. International Journal of Contemporary Management, 2014, 84-96.
• 24. Sayer, N. J., Williams, B., 2019. Lean dla bystrzaków. Helion SA, Gliwice
• 25. Shah, R., Ward, P. T., 2007. Defining and developing measures of lean production. Journal of Operations Management, 25(4). DOI:10.1016/j.jom.2007.01.019
• 26. Ulewicz, R., Kleszcz, D., Ulewicz, M., 2021. Implementation of Lean Instruments in Ceramics Industries. Management Systems in Production Engineering, 29(3) 203-207. DOI:10.2478/mspe-2021-0025
• 27. Wolniak, R., 2014. Relationship between selected lean management tools and innovations. Zeszyty Naukowe Politechniki Śląskiej. Seria Organizacja i Zarządzanie, 75, 157-266.
• 28. Yadav, O. P., Nepal, B. P., Rahaman, M. M., Lal, V., 2017. Lean Implementation and Organizational Transformation: A Literature Review. EMJ - Engineering Management Journal, 29(1). DOI:10.1080/10429247. 2016.1263914
• 29. Yadav, V., Jain, R., Mittal, M. L., Panwar, A., Sharma, M. K., 2019. An appraisal on barriers to implement lean in SMEs. Journal of Manufacturing Technology Management, 30(1). DOI: 10.1108/JMTM-12-2017-0262
• 30. Zargun, S., Al-Ashaab, A., 2014. Critical Success Factors for Lean Manufacturing: A Systematic Literature Review: An International Comparison between Developing and Developed Countries. Advanced Materials

Uwagi

Opracowanie rekordu ze środków MNiSW, umowa nr SONP/SP/546092/2022 w ramach programu "Społeczna odpowiedzialność nauki" - moduł: Popularyzacja nauki i promocja sportu (2024).