Giuliano Almeida Marodin

Implementing lean production systems: research areas and opportunities for future studies

The increasing use of lean production (LP) by companies from several sectors has substantially increased the amount of publications and different emphases on the subject, which amplifies the need for organisation of that knowledge. This article aims to identify the research areas on LP implementation and to propose research opportunities. The literature review was based on 102 studies published in the years between 1996 and 2012. The studies were divided into six research areas, named: (a) structure and scope of LP systems; (b) factors that influence in the LP implementation; (c) methods for implementing LP systems; (d) LP assessment methods; (e) results of implementing LP systems; and (f) adaptation of LP to particular sectors. The findings suggested that the substantial increase on the amount of publications on LP implementation has created fragmented and dissociated areas that would benefit from integration.

A framework for assessing the use of lean production practices in manufacturing cells

This study introduces a framework for assessing the use of lean production (LP) practices in manufacturing cells (MCs). The development of the framework included four stages: (a) defining LP practices applicable to MC, based on criteria such as the inclusion of practices that workers could observe, interact with and use on a daily basis; (b) defining attributes for each practice, emphasising the dimensions which were typical of their implementation in LP environments; (c) defining a set of evidence and sources of evidence for assessing the existence of each attribute–the sources of evidence included direct observations, analysis of documents, interviews and a feedback meeting to validate the assessment results with company representatives; (d) drawing up a model of the relationships among the LP practices, based on a survey with LP experts. This model supports the identification of improvement opportunities in MC performance based on the analysis of their interfaces. A case study of an MC from an automobile parts supplier is presented to illustrate the application of the framework.

Contextual factors and lean production implementation in the Brazilian automotive supply chain

Purpose This paper aims to understand the patterns of lean production implementation, and the relationship between three context factors (i.e. firm size, positions within the supply chain and time length of the lean initiative) and the adoption of lean production practices in firms of the automotive supply chain in Brazil. Design/methodology/approach The authors collected data from 65 companies of the automotive supply chain in Brazil. For data analysis, first a cluster analysis was performed to identify common characteristics in the companies’ context factors when considering patterns of lean implementation. Then, multivariate analysis of variance was used to investigate the differences between the context factors and the degree of use of lean practices. Findings High lean adopters had better performance than low lean adopters in terms of lead time, inventory and turnover. Firms at the first and second tier of the automotive supply chain were “leaner” than firms at the third tier. Large-sized firms were more likely to have a higher degree of use of lean practices than medium and smaller ones. Some, but not all, lean practices followed these patterns. Results also showed that some lean practices were most commonly adopted at the beginning of the lean journey, whereas others took more time to mature. Originality/value This paper demonstrated how lean practices were implemented at different positions within the supply chain, and the patterns of implementation often followed. It also considers lean in the context of developing countries such as Brazil.

Classification and relationships between risks that affect lean production implementation

Purpose – The purpose of this paper is twofold: to classify the risks that affect the lean production implementation (LPI) process, and to demonstrate how that classification can help to identify the relationships between the risks. Design/methodology/approach – Initially, a survey was conducted to identify the probability and impact of 14 risks in LPI, which had been identified based on a literature review. The sample comprised 57 respondents, from companies in the south of Brazil. An exploratory factor analysis was carried out to analyze the results of the survey, allowing the identification of three groups of risks in LPI. Then, a case study was conducted in one of the companies represented in the survey, in order to identify examples of relationships between the risks. Multiple sources of evidence were used in the case study, such as interviews, observations and documents analysis. Findings – The risks that affect LPI were grouped into three categories: management of the process of LPI, top and middle...

Managing barriers to lean production implementation: context matters

As the barriers to lean production implementation (LPI) are influenced by the context, the search for generalisable barriers, relationships, priorities and control measures is to some extent elusive. This study introduces a framework for managing barriers to LPI in specific companies, which is comprised of five stages: (i) description of the context; (ii) identification of the barriers; (iii) analysis of the influence of the context on the barriers; (iv) analysis of the relationships among the barriers using interpretive structural modelling – this sets a basis for prioritising the barriers; and (v) a feedback meeting to discuss the results of data collection, which also informs on the development of an action plan to control the barriers. The use of the framework is illustrated by a case study of a manufacturing plant. Data collection involved interviews, observations and document analysis. A follow-up visit to the company was conducted 18 months after the initial data collection, in order to identify changes in the context. The framework is a contribution in terms of prescriptive theory related to LPI, and is also a means for the generation of data for developing descriptive theory related to the barriers to LPI.

Identificação de oportunidades de pesquisa a partir de um levantamento da implantação da produção enxuta em empresas do Brasil e do exterior

This paper presents a survey on the lean production (LP) implementation process in 47 Brazilian and foreign companies. Among the main results, the survey pointed out that the respondents are mostly interested in learning about lean organizational culture and value stream mapping. The main drivers for adopting LP are improving competitiveness and the fact that LP is adequate to solve critical production problems. People resistance to changes and difficulties to adapt concepts and practices are the main difficulties during LP implementation. The most frequently used practices are work standardization and visual management. Pull production implementation is the practice of highest priority. The results of this survey, along with the observation data collected during visits to some of the investigated companies, permitted the identification of research opportunities on LP implementation, which are summarized at the end of this article. Resumo: Este artigo apresenta um levantamento do processo de implantacao da Producao Enxuta (PE) em 47 empresas do Brasil e do exterior. Entre os principais resultados, o levantamento revelou que: os temas de maior interesse em ampliar conhecimentos sao a cultura organizacional enxuta e o mapeamento do fluxo de valor; os principais motivos para adotar a PE sao a necessidade de melhorar a competitividade e a adequacao da PE ao combate de problemas criticos da producao; as principais dificuldades na implantacao da PE sao a resistencia das pessoas e a dificuldade na adaptacao de conceitos e praticas; as praticas mais utilizadas sao a padronizacao do trabalho e o gerenciamento visual; a producao puxada e a pratica prioritaria no momento. Os resultados deste levantamento, aliados a observacoes realizadas durante visitas em algumas das empresas, permitiram a identificacao de necessidades e oportunidades para pesquisas sobre a implantacao da PE, as quais sao sumarizadas no final do artigo. Palavras-chave: Producao enxuta. Questionario. Avaliacao de empresas.

Lean production and operational performance in the Brazilian automotive supply chain

The purpose of this paper is to understand how lean production (LP) practices are associated with operational performance in the Brazilian automotive supply chain. A survey was carried out to identify the effect of 11 lean practices on five operational performance metrics. The sample comprised 64 companies of the Brazilian automotive supply chain. Results suggest that Brazilian companies are experiencing reduction of Lead time due to the implementation of total productive maintenance practices; and reducing inventory based on the adoption of just-in-time practices. Nevertheless, there appears to be a significant gap in the way these companies are implementing LP practices, which may hinder the achievement of better operational performance results. The survey was limited to companies from Brazil and, therefore, its findings might not be expanded to other companies or sectors. The results also provide a better understanding regarding LP practices and their individual effect on performance metrics.

Learning organisation and human resources management practices: an exploratory research in medium-sized enterprises undergoing a lean implementation

Despite the fact that Lean Manufacturing (LM) implementation has been widely discussed in the literature, a reduced number of works focus on medium-sized enterprises (MEs). Such gap becomes more evident when searching for works exploring the dimensions of learning organisation (DLO) that surround LM implementation in MEs. This paper aims at assessing DLO maturity and the importance of human resources management (HRM) practices in MEs that are starting LM implementation. We verify the applicability of a method for assessing maturity levels of DLO and HRM practices in seven different MEs. The method was originally conceived for large enterprises well advanced in the lean implementation process; it combines concepts of HRM and organisational learning with lean implementation roadmaps. Adapting the method for application in MEs allows such companies to anticipate and minimise organisational learning problems by conducting appropriate HRM practices, leading to a more effective LM implementation. We conclude that the method is a suitable diagnostic tool for MEs, indicating which phases of the lean roadmap are better prepared to be implemented.

The moderating effect of Lean supply chain management on the impact of Lean shop floor practices on quality and inventory

Purpose The purpose of this paper is to understand the relationship between the implementation of Lean shop floor (LSF) practices and Lean supply chain management, and their effect on quality and inventory turnover. Design/methodology/approach A survey-based research method was conducted and data were collected from 110 plants located in Brazil. The research constructs were validated through rigorous procedures (unidimensionality and discriminant validity and reliability) through confirmatory factor analysis and two hypotheses were tested using ordinary least square regression. Findings The results indicate that: Lean supplier relationship positively moderates the effect of LSF practices on inventory turnover; Lean customer relationship negatively moderates the effect of LSF practices on inventory turnover; and Lean supplier relationship positively moderates the effect of LSF practices on quality. Originality/value From a theoretical perspective, the results of this study provide evidences supporting the importance of understanding the systemic relationships between Lean implementation at the shop floor and the firm’s relationships with supply chain partners, that was not tested before. As managerial implications, the results suggest that managers should take a decision to foster a Lean supply chain management depending on which performance metrics they need to improve: quality or inventory turnover.

Lean leadership competencies: a multi-method study

The purpose of this paper is to define the individual leadership competencies that are necessary to implement and sustain lean systems, based on a multi-method approach.,Data collection involved a literature review of lean competencies, interviews with four experts from the university and the industry, and an empirical survey answered by 91 respondents, who represented companies from several sectors. These techniques provided a mix of qualitative and quantitative data, which set a basis for identifying a list of competencies and discussing its validity.,In total, 16 lean leadership competencies were identified and validated, in terms of content validity, face validity, and predictive validity. Regarding this latter validity type, the survey results indicated that the competencies are positively associated with key operational performance indicators, organizational maturity level of lean, and leaders’ experience with lean systems.,The identified list of competencies may be a basis for the development of formal lean leadership development programs. The list may also support the design of tools for assessing the competencies of leaders in lean companies.,A list of 16 lean leadership competencies was developed based on a verifiable research method that used a mix of data collection techniques. This methodological approach is a distinctive characteristic in comparison with earlier studies, which did not include an empirical validation of the competencies.