Muhamad Zaki Yusup

Implementation of lean practices based on Malaysian manufacturers' perspective: a confirmatory factor analysis

This article aims to explore the most significant indicator and factor that drive the implementation of lean production, primarily by Malaysian manufacturers. Using a survey data from 107 respondents, the analysis disclosed that the ability to improve the quality of products, increase the productivity and the operation efficiency was the greatest impact that was achieved from the implementation of lean production practices by Malaysian manufacturers. From an exploratory factor analysis, process optimisation, layout arrangement and work organisation were understood as the main component that encourages the implementation of lean production practices. The findings was confirmed using confirmatory factor analysis, showing that all the practice indicators that were assessed and the factors suggested is consistent with the current practice of lean production in the population studied. This provides a valuable input in making a strategic decision in designing and implementing the realistic systems of lean production for optimum results.

Basic formation in streamlining lean practices in manufacturing operations - a review

Lean production, also known as lean manufacturing was a popular social-technical management philosophy, and widely accepted as an effective approach in improving the operational performance management since it was first introduced in the early 90s. However, most of lean practice is often adopted based on own understanding with reference to the success achieved by others. This potentially creates the gap and eventually affects its implementation performance. Therefore, the aims of this article is to propose based on literature, the basic concept of lean practices that can be considered by manufacturers as a starting point or to strengthen the performance of its regardless of firm size (small, medium or large manufacturing industry). By referring to the nine categories of manufacturing waste (inventory, waiting time, transportation, inefficient energy utilisation, over-processing, over-production, unnecessary motion, and defects), lean practices can be streamlined through the four formation stages, i.e., planning and product development, production planning and scheduling, manufacturing processes, and functional and visual inspection. This can be realised by focusing on three dimensions of implementation, namely input, product revolutionary processes, and output. The proposed concept is useful as a basic guideline, primarily for manufacturers to plan and develop a better strategy for a better performance results.

The Relation between Manufacturing Sustainability and Lean Production in Malaysian Industries - An Initial Study

A diversity of techniques and practices in Lean Production (LP) as a tool for cultivating a culture of continuous improvement has successfully produced a holistic approach in achieving a high level of sustainability in manufacturing. Therefore, this study was undertaken to investigate the current performance of manufacturing sustainability in manufacturing industry in Malaysia, and the contribution of Lean in manufacturing sustainability. The findings show that manufacturing industry in Malaysia has a high sustainability in social competency, followed by economic and environmental competency. Even though the environmental sustainability is ranked lowest, the result reveals that aiming to have better control in environment and labour safety is crucial in producing high quality products. In addition, the correlation analysis reveals that this situation has a high relation to the adoption of Lean in production operations. A high competency in adapting Lean does not just increase the manufacturing efficiency, but also has a substantial influence in producing a sustainable product. This indicates that Lean is not just suitable in fulfilling the manufacturing function, but has the potential to be adapted comprehensively, primarily in achieving high manufacturing sustainability.

The Adoption of Lean and Cleaner Production – A Preliminary Study for Malaysia Manufacturing Industry

Adoption of lean production in managing the production operations with a cleaner production due to of environmental concerns positively drive new manufacturing paradigm in the manufacturing environment. This leads to this study being carried out, in order to investigate the extent of which these practices has been adopted in Malaysia’s manufacturing industry. The finding revealed that good performance in environmental practice in tandem with the appraisal of labour safety in material handling has helped the respondents to successfully sustain the quality and durability of products, improves the operation efficiency, as well as production’s productivity. Aside from that, the correlation test results between all items in LP and CP have a significant positive relationship with each other where the appraisal in the selection of equipment from CP practices have a very strong relationship with the improvement of working conditions that resulted from the adoption of LP practices. These potentially make both practices as the best approach that has potential to be integrated together to support the development of a sustainable manufacturing practice principally in Malaysia’s manufacturing industry.