Guilherme Luz Tortorella

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

Purpose n n n n nThis 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. n n n n nDesign/methodology/approach n n n n nThe 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. n n n n nFindings n n n n nHigh 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. n n n n nOriginality/value n n n n nThis 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.

Method for assessing human resources management practices and organisational learning factors in a company under lean manufacturing implementation

The implementation of lean production systems is deemed essential for companies that wish to obtain high levels of competitiveness. There are several examples in the literature discussing the adoption of lean roadmaps; however, since such maps emphasise technical factors of lean change, the organisational learning (OL) process and human resources management (HRM) practices tend to be neglected. This article presents a method for assessing the impact of HRM practices and OL factors in a company under lean implementation. The method incorporates concepts of HRM and OL into lean implementation roadmaps, enabling a maturity analysis regarding dimensions of OL at different contextualisation levels, and allowing the proposition of improvements in HRM practices. The proposed method is illustrated in a case study from the automotive parts manufacturing sector.

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.

Implementation of lean supply chain: an empirical research on the effect of context

Purpose n n n n nThe purpose of this paper is to empirically investigate the effect of a set of contextual variables on the implementation of lean supply chain (LSC) practices. The authors do that by investigating one main research question: “how do the contextual variables (i.e. plant size, supply chain level, level of onshore suppliers and age of the LM initiative) influence on the degree of adoption of LSC practices?” n n n n nDesign/methodology/approach n n n n nTo this end, the authors collected data from 115 companies from different sectors located in Southern Brazil. Data collected was analyzed by means of multivariate techniques. The authors tested if the frequency of observations for each contextual variable was associated to the implementation levels of the LSC practices. n n n n nFindings n n n n nThe evidences suggest that supply chain context significantly impacts the likelihood of implementing LSC practices. In particular, the influence of tier level, plant size and larger experience in implementing LM seems to be substantial across a wide mix of practices. On the other hand, results indicate that contexts in which companies are still beginners at the lean journey and their level of onshore suppliers appear to be less pervasive than previous empirical researches imply. n n n n nOriginality/value n n n n nThe implementation of LSC practices entails a different business model, in which improved profits arise from the cooperation rather than bargaining or imposing power over supply chain partners. However, not all organizations should implement the same set of practices, since the adoption of any specific management practice depends upon a set of contextual variables. The understanding of the relationship between the level of adoption of LSC practices and the contextual variables helps to anticipate occasional difficulties and sets the proper expectations along the implementation.

Análise do fluxo de valor sob uma perspectiva estocástica

Lean Production (LP) emerges as a response to the increase in competitiveness in a globalized market. Among the practices utilized in LP, value stream mapping (VSM) is one of the most adopted, as it identifies wastes and direct the application of other LP practices. VSM maps material flows and production control information. However, VSM has a deterministic approach, which limits the power of modeling and makes it difficult to map dynamic models. In this sense, this work has the goal of proposing a method for the identification of opportunities for improvements that combine VSM and Monte Carlo simulation, taking into account the uncertainties of the value flow. The results show that this new approach allows the identification of improvement opportunities that are not contemplated in a traditional application of the VSM.

Planejamento sistemático de layout aplicado à cozinha industrial de um restaurante temático

Remodeling the layout of a company is a widely used practice with the purpose of improving continually its productive and information flows. In the restaurant business, it is important to consider which factors influences the quality of the service to propose, based on them, the best arrangement of workstations and, consequently, obtain the best operational efficiency. The objective of this article is, therefore, to plan the layout of the production area of an industrial kitchen of a themed restaurant, located in Novo Hamburgo, Rio Grande do Sul, through the application of the Systematic Layout Planning methodology. Moreover, as a way of supporting the selection criteria of the best layout alternative, it is suggested, throughout the collection and analysis of bibliographical reference, to establish the layout indicators with specific application in the restaurant business. From this definition, it is used MAUT for helping the decision making process in order to direct the choice of the best layout option. The results intend to decrease both the amount of storage and the employees movement around the facility, so that an improvement can be achieved.

Avaliação das Dimensões de Aprendizagem Organizacional e do Gerenciamento de Pessoas na Produção Enxuta: Pesquisa em Empresas de Médio Porte

Despite the fact that Lean Manufacturing (LM) imple mentation has widely been discussed in literature, little has been evidenced involving medium-sized enterprises (MEs). This gap is significantly increased when the Organi zational Learning (OL) dimensions that surround the LM implementation in MEs are added to the problem. Thus, this paper aims to assess the OL dimensions maturity and the People Ma nagement Practices (PMP) importance in MEs that are beginning LM implementation. This r esearch verifies the application of an existent method, originally conceived for large ent erprises, and consolidates the results from seven different MEs in order to propose a general a pproach for the problem. This approach allows MEs anticipate and minimize OL issues by dri ving the appropriate PMP and providing a more effective LM implementation sustainability .