Purpose – The purpose of this paper is to report a pilot study on lean awareness and implementation using the survey data collected from about 32 industries situated in western and eastern region of India. Design/methodology/approach – A survey instrument containing 45 statements was designed to assess respondents’ attitude and awareness toward lean practices and to explore the level of lean implementation in the organization. The instrument was distributed personally or through mail to the employees of 32 industries and they were supported for any query about the questions. Descriptive statistical analysis, hierarchical cluster analysis and ANOVA were used to analyze the data with SPSS statistical software. Findings – The research uncovers the fact that the current status of lean implementation and awareness in Indian industries is not so encouraging and the reason for that is, the human-related issues are not tackled properly. Quality and process technology, are the two key areas where industries are in...

Status of lean manufacturing practices in Indian industries and government initiatives

The interest of lean companies in tools to monitor and control their lean implementation process, ie their leanness level, is continuously increasing A multitude of diverse approaches have been 

Leanness measurement methods in manufacturing organisations: a systematic review

Past literature has investigated the relationship between lean production and financial performance with mixed results. Most studies focused on subsets of lean practices to measure lean production,...

Degree of leanness and lean maturity: exploring the effects on financial performance

This paper aims to discuss the concept of leanness and provide an effective assessment tool for measuring leanness of small and medium enterprises (SMEs).,A hybrid interpretive structural modelling–analytical network process (ISM-ANP) approach is used to develop leanness index for SMEs. The parameters for leanness are extracted from the literature survey, and the inter-relationships among them are identified through ISM approach. Further, the ANP tool is used to derive the weights of the parameters, and the leanness index is developed for SMEs.,A leanness assessment model is developed, which considers the interdependencies among leanness parameters. Continuous improvement, Just in Time and active management participation, respectively, get first, second and third ranks for leanness measurement in SMEs.,This study is based on the expert’s opinion, and it may tend to be biased. However, future study will be performed as empirical research to catch more explicit concept and more insights of leanness in context of SME sector.,This paper provides guidelines to the managers of SMEs for measuring the leanness index and planning for future. This leanness index gives information regarding the degree of lean adoption in the organization.,The proposed model has been developed by the expert opinion of academicians and practitioners. The proposed model can provide guidelines and directions for managers for leanness assessment in SME context.

Development of leanness index for SMEs

Purpose




The retail revolution swing from traditional distribution to e-tailing services and unprecedented increase in internet adoption insist practitioners to diversely plan warehousing strategies. More than practically required storage space has been identified as wastes, and also it does not improve performance. An organized framework integrating storage design policies, operational performance and customer value improvement for retail-distribution management is lacking. Therefore, the purpose of this paper is to develop broad guidelines to design the “just-right” amount of forward area, i.e., “lean buffer” answering the following questions: “What should be lean buffer size? How effective the forward area is? As per demand variations, which storage waste (SKU) should be allocated with how much storage space? What is the amount of storage waste (SW)? How smooth the material flow is in between reserve-forward area?” for storage allocation in cosmetics distribution centers.




Design/methodology/approach




After forecasting static storage allocation between two planning horizons, if a particular SKU is less or non-moving, then it will cause SW, as the occupied location can be utilized by other competing SKUs, and also it impedes material flow for an instance. A dynamically efficient and self-adaptive, knapsack instance based heuristics is developed in order to make effective storage utilization.




Findings




The existing state-of-the-art under study is supported with a distribution center case, and the study investigates the need of a model adopting lean management approach in storage allocation policies along with test results in LINGO. The sensitivity analysis describes the impact of varying demand and buffer size on performance. The results are compared with uniform and exponential distributed demands, and findings reveal that the proposed heuristics improves efficiency and reduce SWs in forward-reserve area.




Originality/value




The presented model demonstrates a novel thinking of lean adoption in designing storage allocation strategy and its performance measures while reducing wastes and improving customer value. Future research issues are highlighted, which may be of great help to the researchers who would like to explore the emerging field of lean adoption for sustainable retail and distribution operations.

Storage allocation framework for designing lean buffers in forward-reserve model: a test case

Purpose – The purpose of this paper is to develop a decision support system (DSS) for multi grade fuzzy leanness assessment (MGFLA) (DSS‐MGFLA).Design/methodology/approach – The assessment of leanness gains vital importance. Due to the drawbacks associated with conventional approaches, fuzzy methods are gaining importance. In this context, multi‐grade fuzzy method has been used for leanness assessment. Since the computation is time consuming and error‐prone, a computerized DSS known as DSS‐MGFLA has been developed.Findings – DSS‐MGFLA enables the accurate evaluation of leanness. Besides assessing leanness, DSS also enables the identification of improvement areas. The DSS has been validated in an Indian relays manufacturing organization. Based on the validation, its practical feasibility has been ensured.Research limitations/implications – DSS‐MGFLA has been validated in a single manufacturing organization for its working feasibility. But the findings could be extended to similar manufacturing organization...

Development of computerized decision support system for leanness assessment using multi grade fuzzy approach

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Development of computerized decision support system for leanness assessment using multi grade fuzzy approach