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Defining Lean Production : Some conceptual and practical issues

09 Dec 2008-Iss: 033, pp 285-300
TL;DR: In this paper, the authors investigate the definition of Lean Production and the methods and goals associated with the concept as well as how it differs from other popular management concepts, and conclude that Lean Production is not clearly defined in the reviewed literature.
Abstract: Purpose - This paper aims to investigate the definition of Lean Production and the methods and goals associated with the concept as well as how it differs from other popular management concepts. Methodology/Approach - The paper is based on a review of the contemporary literature on Lean Production, both journal articles and books. Findings - It is shown in the paper that there is no consensus on a definition of Lean Production between the examined authors. The authors also seem to have different opinions on which characteristics that should be associated with the concept. Overall it can be concluded that Lean Production is not clearly defined in the reviewed literature. This divergence can cause some confusion on a theoretical level, but is probably more problematic on a practical level when organizations aim to implement the concept. This paper argues that it is important for an organization to acknowledge the different variations, and to raise the awareness of the input in the implementation process. It is further argued that the organization should not accept any random variant of Lean, but make active choices and adapt the concept to suit the organization-s needs. Through this process of adaptation, the organization will be able to increase the odds of performing a predictable and successful implementation. Originality/Value - This paper provides a critical perspective on the discourse surrounding Lean Production, and gives an input to the discussion of the implementation of management models. Keywords - Lean Production, Definition, Construct Validity, Total Quality Management Paper type - Conceptual paper
Citations
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Posted Content
TL;DR: Deming's theory of management based on the 14 Points for Management is described in Out of the Crisis, originally published in 1982 as mentioned in this paper, where he explains the principles of management transformation and how to apply them.
Abstract: According to W. Edwards Deming, American companies require nothing less than a transformation of management style and of governmental relations with industry. In Out of the Crisis, originally published in 1982, Deming offers a theory of management based on his famous 14 Points for Management. Management's failure to plan for the future, he claims, brings about loss of market, which brings about loss of jobs. Management must be judged not only by the quarterly dividend, but by innovative plans to stay in business, protect investment, ensure future dividends, and provide more jobs through improved product and service. In simple, direct language, he explains the principles of management transformation and how to apply them.

9,241 citations

Journal ArticleDOI
TL;DR: A review of Lean Manufacturing (LM) literature can be found in this paper, where the authors highlight the divergent definitions, scopes, objectives, and tools/techniques/methodologies.
Abstract: Purpose – The advent of recession at the beginning of twenty-first century forced many organizations worldwide to reduce cost and to be more responsive to customer demands. Lean Manufacturing (LM) has been widely perceived by industry as an answer to these requirements because LM reduces waste without additional requirements of resources. This led to a spurt in LM research across the globe mostly through empirical and exploratory studies which resulted in a plethora of LM definitions with divergent scopes, objectives, performance indicators, tools/techniques/methodologies, and concepts/elements. The purpose of this paper is to review LM literature and report these divergent definitions, scopes, objectives, and tools/techniques/methodologies. Design/methodology/approach – This paper highlights various definitions by various researchers and practitioners. A total of 209 research papers have been reviewed for the research contribution, research methodology adopted, tools/techniques/methodologies used, type of industry, author profile, country of research, and year of publication. Findings – There are plethora of LM definitions with divergent objectives and scope. Theory verification through empirical and exploratory studies has been the focus of research in LM. Automotive industry has been the focus of LM research but LM has also been adopted by other types of industries also. One of the critical implementation factors of LM is simultaneous adoption of leanness in supply chain. LM has become an integrated system composed of highly integrated elements and a wide variety of management practices. There is lack of standard LM implementation process/framework. Originality/value – The paper reviews 209 research papers for their research contribution, research methodology, author profile, type of industry, and tools/techniques/methodology used. Various characteristics of LM definitions are also reviewed.

665 citations

Journal ArticleDOI
TL;DR: This study critically reviewed 18 articles describing the implementation of Lean in 15 EDs in the United States, Australia, and Canada and revealed numerous ED process changes, often involving separate patient streams, accompanied by structural changes such as new technologies, communication systems, staffing changes, and the reorganization of physical space.

484 citations

Journal ArticleDOI
TL;DR: This article identifies four main research streams concerning the link between Industry 4.0 and lean manufacturing, and a research agenda for future studies is proposed.
Abstract: In recent years, Industry 4.0 has emerged as one of the most discussed concepts and has gained significant popularity in both academia and the industrial sector. Both Industry 4.0 and lean manufact...

481 citations

Journal ArticleDOI
TL;DR: It is indicated that LP practices are positively associated with Industry 4.0 technologies and their concurrent implementation leads to larger performance improvements, although not all aspects matter to the same extent and effect.
Abstract: The adoption of Industry 4.0 technologies has been deemed as a strategy to increase product quality and make manufacturing processes more efficient. However, the way that these technologies are int...

445 citations

References
More filters
Posted Content
TL;DR: Deming's theory of management based on the 14 Points for Management is described in Out of the Crisis, originally published in 1982 as mentioned in this paper, where he explains the principles of management transformation and how to apply them.
Abstract: According to W. Edwards Deming, American companies require nothing less than a transformation of management style and of governmental relations with industry. In Out of the Crisis, originally published in 1982, Deming offers a theory of management based on his famous 14 Points for Management. Management's failure to plan for the future, he claims, brings about loss of market, which brings about loss of jobs. Management must be judged not only by the quarterly dividend, but by innovative plans to stay in business, protect investment, ensure future dividends, and provide more jobs through improved product and service. In simple, direct language, he explains the principles of management transformation and how to apply them.

9,241 citations

Book
01 Jan 2003
TL;DR: The authors describe in detail how managers in a wide range of companies and industries - small, medium and large, North American, European and Japanese - transformed their business by applying the principles of lean thinking.
Abstract: If The Machine That Changed the World is a description of the Toyota system in the industry of its origin, Lean Thinking is a generalization of the basic concepts so they can be applied to any company in any industry. The authors begin by summarizing the five inherent principles in any lean system: 1 correctly specify value so you are providing what the customer actually wants, 2 identify the value stream for each product family and remove the wasted steps that don't create value but do create muda (waste), 3 make the remaining value-creating flow continuously to drastically shorten throughput times, 4 allow customer to pull value from your rapid-response value streams as needed (rather than pushing products toward the customer on the basis of forecasts), and 5 never relax until you reach perfection, which is the delivery of pure value instantaneously with zero muda. (The first part of Lean Thinking devotes a chapter to each of these principles.) In the second part, the authors describe in detail how managers in a wide range of companies and industries - small, medium and large, North American, European and Japanese - transformed their business by applying the principles of lean thinking. Chapters are devoted to Pratt and Whitney, Wiremold, Lantech in North America, Porsche in Germany, and Showa Manufacturing in Japan. Lean Thinking has sold more than 300,000 copies in the English language hard-cover version alone, because it's an indispensable companion for every manager making the lean journey.

5,071 citations

Book
01 Mar 1988
TL;DR: In this paper, Taiichi Ohno shares the genius that sets him apart as one of the most disciplined and creative thinkers of our time, and combines his candid insights with a rigorous analysis of Toyota's attempts at Lean production.
Abstract: In this classic text, Taiichi Ohno--inventor of the Toyota Production System and Lean manufacturing--shares the genius that sets him apart as one of the most disciplined and creative thinkers of our time. Combining his candid insights with a rigorous analysis of Toyota's attempts at Lean production, Ohno's book explains how Lean principles can improve any production endeavor. A historical and philosophical description of just-in-time and Lean manufacturing, this work is a must read for all students of human progress. On a more practical level, it continues to provide inspiration and instruction for those seeking to improve efficiency through the elimination of waste.

3,273 citations

Book
01 Jan 2004
TL;DR: The "Toyota Way" as mentioned in this paper is a set of 14 management principles and philosophy that drive Toyota's quality and efficiency-obsessed culture, and can be applied to any business process, whether in services or manufacturing.
Abstract: 'This book will give you an understanding of what has made Toyota successful and some practical ideas that you can use to develop your own approach to business' - Gary Convis, Managing Office of Toyota. Fewer man-hours. Less inventory. The highest quality cars with the fewest defects of any competing manufacturer. In factories around the globe, Toyota consistently raises the bar for manufacturing, product development, and process excellence. The result is an amazing business success story: steadily taking market share from price-cutting competitors, earning far more profit than any other automaker, and winning the praise of business leaders worldwide."The Toyota Way" reveals the management principles behind Toyota's worldwide reputation for quality and reliability. Dr. Jeffrey Liker, a renowned authority on Toyota's Lean methods, explains how you can adopt these principles - known as the 'Toyota Production System' or 'Lean Production' - to improve the speed of your business processes, improve product and service quality, and cut costs, no matter what your industry.Drawing on his extensive research on Toyota, Dr.Liker shares his insights into the foundational principles at work in the Toyota culture. He explains how the Toyota Production System evolved as a new paradigm of manufacturing excellence, transforming businesses across industries. You'll learn how Toyota fosters employee involvement at all levels, discover the difference between traditional process improvement and Toyota's Lean improvement, and learn why companies often think they are Lean-but aren't. The fourteen management principles of the "Toyota Way" create the ideal environment for implementing Lean techniques and tools.Dr. Liker explains each key principle with detailed, examples from Toyota and other Lean companies on how to: foster an atmosphere of continuous improvement and learning; create continuous process 'flow' to unearth problems; satisfy customers (and eliminate waste at the same time); grow your leaders rather than purchase them; get quality right the first time; and grow together with your suppliers and partners for mutual benefit.Dr.Liker shows the Toyota Way in action, then outlines how to apply the "Toyota Way" in your organization, with examples of how other companies have rebuilt their culture to create a Lean, learning enterprise. "The Toyota Way" is an inspiring guide to taking the steps necessary to emulate Toyota's remarkable success. What can your business learn from Toyota? How to double or triple the speed of any business process? How to build quality into workplace systems? How to eliminate the huge costs of hidden waste? How to turn every employee into a quality control inspector? How to dramatically improve your products and services! With a market capitalization greater than the value of General Motors, Ford, and Chrysler combined, Toyota is also, (by far), the world's most profitable automaker.Toyota's secret weapon is Lean production - the revolutionary approach to business processes that it invented in the 1950's and has spent decades perfecting. Today businesses around the world are implementing Toyota's radical system for speeding up processes, reducing waste, and improving quality. "The Toyota Way", explains Toyota's unique approach to lean - the 14 management principles and philosophy that drive Toyota's quality and efficiency-obsessed culture. You'll gain valuable insights that can be applied to any organization and any business process, whether in services or manufacturing.Professor Jeffrey Liker has been studying Toyota for twenty years, and was given unprecedented access to Toyota executives, employees and factories, both in Japan and the United States, for this landmark work. The book is full of examples of the 14 fundamental principles at work in the Toyota culture, and how these principles create a culture of continuous learning and improvement. You'll discover how the right combination of long-term philosophy, process, people, and problem solving can transform your organization into a Lean, learning enterprise - the Toyota Way.

3,174 citations

Journal ArticleDOI
TL;DR: In this paper, the effects of three contextual factors, plant size, plant age and unionization status, on the likelihood of implementing 22 manufacturing practices that are key facets of lean production systems are examined.

2,576 citations