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A methodology for effective implementation of lean strategies and its performance evaluation in manufacturing organizations

Azharul Karim (School of Engineering Systems, Queensland University of Technology, Brisbane, Australia)
Kazi Arif‐Uz‐Zaman (School of Engineering Systems, Queensland University of Technology, Brisbane, Australia)

Business Process Management Journal

ISSN: 1463-7154

Article publication date: 1 February 2013

14605

Abstract

Purpose

The purpose of this paper is to develop an effective methodology for implementing lean manufacturing strategies and a leanness evaluation metric using continuous performance measurement (CPM).

Design/methodology/approach

Based on five lean principles, a systematic lean implementation methodology for manufacturing organizations has been proposed. A simplified leanness evaluation metric consisting of both efficiency and effectiveness attributes of manufacturing performance has been developed for continuous evaluation of lean implementation. A case study to validate the proposed methodology has been conducted and proposed CPM metric has been used to assess the manufacturing leanness.

Findings

Proposed methodology is able to systematically identify manufacturing wastes, select appropriate lean tools, identify relevant performance indicators, achieve significant performance improvement and establish lean culture in the organization. Continuous performance measurement matrices in terms of efficiency and effectiveness are proved to be appropriate methods for continuous evaluation of lean performance.

Research limitations/implications

Effectiveness of the method developed has been demonstrated by applying it in a real life assembly process. However, more tests/applications will be necessary to generalize the findings.

Practical implications

Results show that applying the methods developed, managers can successfully identify and remove manufacturing wastes from their production processes. By improving process efficiency, they can optimize their resource allocations. Manufacturers now have a validated step by step methodology for successfully implementing lean strategies.

Originality/value

According to the authors' best knowledge, this is the first known study that proposed a systematic lean implementation methodology based on lean principles and continuous improvement techniques. Evaluation of performance improvement by lean strategies is a critical issue. This study develops a simplified leanness evaluation metric considering both efficiency and effectiveness attributes and integrates it with the lean implementation methodology.

Keywords

Citation

Karim, A. and Arif‐Uz‐Zaman, K. (2013), "A methodology for effective implementation of lean strategies and its performance evaluation in manufacturing organizations", Business Process Management Journal, Vol. 19 No. 1, pp. 169-196. https://doi.org/10.1108/14637151311294912

Publisher

:

Emerald Group Publishing Limited

Copyright © 2013, Emerald Group Publishing Limited

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