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Implementation status of lean management in Polish manufacturing enterprises

Stronczek Anna

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

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2024

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z. 191

519--540

EN

Purpose: The aim of this study was to assess the extent of Lean Management implementation in Polish manufacturing enterprises that declare the adoption of the lean philosophy. The study also aimed to identify areas for further development and provide practical recommendations for companies seeking to enhance their Lean Management practices. Design/methodology/approach: A quantitative approach was employed, utilizing a survey of Polish manufacturing enterprises to assess the degree of implementation of Lean Management principles in key areas such as customer relationships, supplier relationships, employee engagement, Total Productive Maintenance (TPM), and pull/flow processes. The comprehensive survey covered a wide range of Lean Management practices and was administered online to a sample of Polish manufacturing enterprises. Data from the survey was analyzed using a variety of statistical techniques, including descriptive statistics, correlation analysis, and regression analysis. The data was used to identify patterns and trends in Lean implementation practices. Findings: The results of the study indicated that Lean Management practices are relatively well-established in Polish manufacturing enterprises in each of the assessed areas. However, significant differences were observed between areas, with the highest levels of implementation observed in customer relationships and employee engagement, and the lowest in supplier relationships and pull/flow processes. Research limitations/implications: The primary limitations of the study lie in its reliance on self-assessment data and the potential bias of respondents. Additionally, the generalization of results is limited to a specific sample of Polish manufacturing enterprises. Nevertheless, the study provides valuable insights into the current state of Lean Management implementation in Poland and identifies areas for further development. Practical implications: The study suggests that Polish manufacturing enterprises should prioritize the continued implementation of lean practices in the areas of supplier relationships and pull/flow processes. This requires coordinated efforts to strengthen supplier relationships, optimize supply chain management, and implement lean production principles to eliminate waste and enhance efficiency. Originality/value: The study contributes to existing knowledge on Lean Management implementation by providing a comprehensive assessment of its current state in Polish manufacturing enterprises. The findings offer practical guidance for companies seeking ways to improve their Lean Management practices and derive associated benefits.

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Lean Manufacturing Practices Assessment Case Study of Automotive Company

Hąbek Patrycja, Lavios Juan J, Grzywa Adam

Production Engineering Archives

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2023

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Vol. 29, Iss. 3

311-318

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.

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Lean journey success factors - a case study of lean tools implementation sequence in a manufacturing company

Urban Wiesłąw, Tochwin Daniel

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

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2022

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z. 162

703--720

EN

Purpose: The study aim is an in-depth investigation of a Lean tools implementation sequence in an organisation as an expression of a Lean journey within that organisation. The success factors of Lean tools implementation and the relationship between them are studied. A model of Lean tools implementation in an organisation is aimed to be developed. Design/methodology/approach: A case study method is employed in this study. It is conducted in a manufacturing company from the fast-moving consumer goods (FMCG) industry. The employed method allows exploitation of a variety of techniques in the investigation process: in-depth interviews, observations, documents and data analysis. The study takes into consideration a systematic literature review and bibliometric network analysis supported by the Vosviewer software tool. Findings: The implementation of Lean Manufacturing approach, along with accompanying tools and methods, is aimed at efficiency and/or quality results of the processes within a company. Selected tools, to be successfully implemented, should support the elimination or reduction of losses related to current process flows. There are many Lean tools available, but most do not fit all organisations and all the kinds of manufacturing processes. Therefore, proper preparation before implementation is an essential issue for any organisation striving for Lean outcomes. The available Lean tools, along with their implementation sequences, are not studied comprehensively in the literature. Originality/value: An organisational-development-driven model of Lean tools implementation is elaborated, based on the literature and empirical investigations. The decision to choose the appropriate Lean tool should be guided by general organisational development. Several factors need to be considered before the implementation process, namely, capabilities, resources, gains and return on expenditure. Top management engagement, appropriate communication and listening to line employees look to be key success factors in Lean tools implementation.

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Interpretive structural modeling of identified success factors to lean implementation in SMEs

Shrimali Arvind Kumar

Quality Production Improvement - QPI

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2019

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Vol. 1, Iss. 1

69--77

EN

Lean practices are implemented in manufacturing enterprises to find hidden waste and attain continuous improvement. Various enterprises have experienced benefits owing to the Lean implementation. Following the use of appropriate lean instruments and techniques, there are many factors that affect successful lean implementation process. Researchers have identified a large number of these success factors to implementation of Lean. Understanding these enablers and the interactions between them can be crucial to the success of lean implementation. Interpretive Structural Modeling (ISM) is one of the established methodologies to bring forward the interrelationships among parameters of an issue or a problem. The purpose of this paper is to create the hierarchy of the various success factors to Lean Implementation according to their importance using the approach of ISM to facilitate Small and Medium enterprises (SMEs) across India.

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Opportunities of lean thinking in improving the competitiveness of the HUNGARIAN SME sector

Koloszár L.

Management and Production Engineering Review

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2018

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Vol. 9, No. 2

26--41

EN

One of the key factors of a competitive economy is creating a strong, internationally competitive SME sector. This essay is based on the fact that management tools used in the SME sector are insufficient. With the development of these tools, the competitiveness of companies could improve. According to the literature, using lean thinking has a positive influence on the company’s effectiveness, and also proved that lean approach can be successfully extended out of the car industry, into the limitedly resourced SME sector, too. Even though the topic of lean manufacturing is analysed by many studies, there is a lack of papers dealing with its usage in the SME sector. The originality of this paper lies in analysing the current status of using lean manufacturing practices among the Hungarian SMEs operating in the manufacturing industry. The paper includes an examination about how deeply the elements of lean thinking are present in the Hungarian SME sector, how large the development reserves are, and whether there is a difference between the usage of lean practices. A structured questionnaire was used for data collection. SMEs’ representatives, mostly CEOs and managers from the Hungarian manufacturing industry participated in the survey. The sample contained 128 observations. The study has two control variables, which are the size of the company and the relation to the lean management. The survey brought the following results. First of all, it shows that the level of using lean is low among the Hungarian SMEs. Furthermore, customer orientation is a key factor in the sector, however, there are considerable possibilities for progress by the inner processes and the handling and involvement of the suppliers. Firstly, a good basis to increase the effectiveness could be the creation of thinking in processes influencing the supply chain. Secondly, the development of the leadership and the involvement of the employees at some level are also significant. Key findings is that without state incitement and the involvement of outside experts, progress cannot be expected to spread on a broad scope. The background of the research method was created to fit the available literature and to capable to be used in other countries, too. Moreover, this way the available information can be expanded with a regional dimension, in case further studies are going to be made.