Lean Manufacturing Implementation in Developing Countries:Evidence from Jordanian Industrial Companies
DOI:
https://doi.org/10.48165/sajssh.2024.5501Keywords:
Lean Implementation, Developing Country, , Industrial Companies, JordanAbstract
In today's fiercely competitive landscape, industries are increasingly embracing lean manufacturing strategies for survival. However, the adoption of lean principles in Jordanian manufacturing sectors remains relatively new. This study aims to evaluate the current state of lean adoption in Jordanian industries, focusing on its techniques, motivations, and challenges. Employing a quantitative methodology, surveys targeted Production, Operation, and Quality Managers in Jordanian organizations. Out of 300 distributed questionnaires, 176 valid responses were received, representing a response rate of 58.7%. The findings indicate a relatively low adoption of lean practices in Jordanian industries, though firms that have implemented lean report significant benefits, particularly in quality enhancement and cost reduction. Key challenges include inadequate training, a scarcity of experts, and complexities in small batch production. While the study's sample size is limited, caution is warranted in interpreting the results. Further empirical research is needed to quantify the performance benefits of lean adoption. This study sheds light on lean adoption in Jordanian manufacturing, informing knowledge development and guiding future efforts to promote lean practices in the industrial landscape.
References
Aadithya, B. G., Asokan, P., & Vinodh, S. (2023). Lean manufacturing in fabrication industry: literature review and framework proposal. International Journal of Quality & Reliability Management, 40(6), 1485–1517. https://doi.org/10.1108/ijqrm-03-2021-0084
Abdullah Hokoma, R., Khan, M. K., & Hussain, K. (2008). Investigation into the implementation stages of manufacturing and quality techniques and philosophies within the Libyan cement industry. Journal of Manufacturing Technology Management, 19(7), 893–907. https://doi.org/10.1108/17410380810898804
Abdullah Hokoma, R., Khurshid Khan, M., & Hussain, K. (2010). The present status of quality and manufacturing management techniques and philosophies within the Libyan iron and steel industry. The TQM Journal, 22(2), 209–221. https://doi.org/10.1108/17542731011024309
Ahmad, M., Dhafr, N., Benson, R., & Burgess, B. (2005). Model for establishing theoretical targets at the shop floor level in specialty chemicals manufacturing organizations. Robotics and Computer-Integrated Manufacturing, 21(4–5), 391–400. https://doi.org/10.1016/j.rcim.2004.11.016
Al-Madi, F. (2017). The impact of supply chain management practices on supply chain performance in the Jordanian Industrial Sector. European Journal of Business and Management, 9(15), 150–165.
Al-Madi, Faisal, Alfalah, T., Shraah, A. A., & Abu-Rumman, A. (2021). Supply chain practices and organizational performance: Evidence from Jordanian medical devices firms. Uncertain Supply Chain Management, 9(4), 831–840. https://doi.org/10.5267/j.uscm.2021.8.006
Almasarweh, M. S. (2020). The applicability of lean manufacturing methods and its impact on the performance of the Jordanian industrial companies listed in ASE. Management Science Letters, 3023–3032. https://doi.org/10.5267/j.msl.2020.5.022
Alves, R. F., Vieira Neto, J., de Mattos Nascimento, D. L., de Andrade, F. E., Tortorella, G. L., & Garza-Reyes, J. A. (2022). Lean accounting: a structured literature review. The TQM Journal, 34(6), 1547–1571. https://doi.org/10.1108/tqm-06-2021-0185
Amin, M. A., Alam, M. R., Alidrisi, H., & Karim, M. A. (2021). A fuzzy-based leanness evaluation model for manufacturing organisations. Production Planning & Control, 32(11), 959–974. https://doi.org/10.1080/09537287.2020.1778113
Asad, M., Asif, M. U., Sulaiman, M. A. B. A., Satar, M. S., & Alarifi, G. (2023). Open innovation: the missing nexus between entrepreneurial orientation, total quality management, and performance of SMEs. Journal of Innovation and Entrepreneurship, 12(1). https://doi.org/10.1186/s13731-023-00335-7
Asad, M., Kashif, M., Sheikh, U. A., Asif, M. U., George, S., & Khan, G. ul H. (2022). Synergetic effect of safety culture and safety climate on safety performance in SMEs: does transformation leadership have a moderating role? International Journal of Occupational Safety and Ergonomics: JOSE, 28(3), 1858–1864. https://doi.org/10.1080/10803548.2021.1942657
Asad, M., Majali, T., Aledeinat, M., Abdelkarim Almajali, D., & Akhorshaideh, A. H. O. (2023). Green entrepreneurial orientation for enhancing SMEs financial and environmental performance: Synergetic moderation of green technology dynamism and knowledge transfer and integration. Cogent Business & Management, 10(3). https://doi.org/10.1080/23311975.2023.2278842
Asif, M. U., Asad, M., Kashif, M., & Abrar ul Haq, M. (2021). Knowledge exploitation and knowledge exploration for sustainable performance of SMEs. 2021 Third International Sustainability and Resilience Conference: Climate Change.
Ayoogh, A. (2006). Process-Based Implementation of Lean Management System in Jackson and Jones. Power of Company Boards of Mazandaran. Shahid Beheshti University.
Balle, M. (2005). Lean attitude [considering attitude in lean production]. Manufacturing Engineer, 84(2), 14–19. https://doi.org/10.1049/me:20050202
Bashar, A., Hasin, A. A., Sakib, M. N., & Bashar, N. B. (2024). Lean implementation barriers in the apparel industry in Bangladesh. International Journal of Lean Six Sigma. https://doi.org/10.1108/ijlss-12-2022-0249
Bhasin, S. (2012). Prominent obstacles to lean. International Journal of Productivity and Performance Management, 61(4), 403–425. https://doi.org/10.1108/17410401211212661
Billesbach, T. J. (1994). Applying lean production principles to a process facility. Production and Inventory Management Journal, 35(3).
Buer, S.-V., Strandhagen, J. O., & Chan, F. T. S. (2018). The link between Industry 4.0 and lean manufacturing: mapping current research and establishing a research agenda. International Journal of Production Research, 56(8), 2924–2940. https://doi.org/10.1080/00207543.2018.1442945
Chahal, V., & Narwal, M. S. (2017). An empirical review of lean manufacturing and their strategies. Management Science Letters, 321–336. https://doi.org/10.5267/j.msl.2017.4.004
Chen, Z., & Shang, J. S. (2008). Manufacturing planning and control technology versus operational performance: an empirical study of MRP and JIT in China. International Journal of Manufacturing Technology and Management, 13(1), 4. https://doi.org/10.1504/ijmtm.2008.015971
Chowdary, B. V., & George, D. (2011). Improvement of manufacturing operations at a pharmaceutical company: A lean manufacturing approach. Journal of Manufacturing Technology Management, 23(1), 56–75. https://doi.org/10.1108/17410381211196285
Dangayach, G. S., & Deshmukh, S. G. (2003). Evidence of manufacturing strategies in Indian industry: a survey. International Journal of Production Economics, 83(3), 279–298. https://doi.org/10.1016/s0925-5273(02)00372-9
Demirkesen, S. (2021). From Lean manufacturing to Lean construction: How principles, tools, and techniques evolved. In Lean Manufacturing. IntechOpen.
Deros, B. M., Mohamad, D., Idris, M. H. M., Rahman, M. N. A., Ghani, J. A., & Ismail, A. R. (2011). Setup time reduction in an automotive battery assembly line. International Journal of Systems Applications, Engineering & Development, 5(5), 618–625.
Doolen, T. L., & Hacker, M. E. (2005). A review of lean assessment in organizations: An exploratory study of lean practices by electronics manufacturers. Journal of Manufacturing Systems, 24(1), 55–67. https://doi.org/10.1016/s0278-6125(05)80007-x
Gebauer, H., Kickuth, M., & Friedli, T. (2009). Lean management practices in the pharmaceutical industry. International Journal of Services and Operations Management, 5(4), 463. https://doi.org/10.1504/ijsom.2009.024580
Ghosh, M. (2013). Lean manufacturing performance in Indian manufacturing plants. Journal of Manufacturing Technology Management, 24(1), 113–122. https://doi.org/10.1108/17410381311287517
Golroudbary, S. R., & Zahraee, S. M. (2015). System dynamics model for optimizing the recycling and collection of waste material in a closed-loop supply chain. Simulation Modelling Practice and Theory, 53, 88–102. https://doi.org/10.1016/j.simpat.2015.02.001
Gurumurthy, A., & Kodali, R. (2011). Design of lean manufacturing systems using value stream mapping with simulation: A case study. Journal of Manufacturing Technology Management, 22(4), 444–473. https://doi.org/10.1108/17410381111126409
Habib, M. A., Rizvan, R., & Ahmed, S. (2023). Implementing lean manufacturing for improvement of operational performance in a labeling and packaging plant: A case study in Bangladesh. Results in Engineering, 17(100818), 100818. https://doi.org/10.1016/j.rineng.2022.100818
Holweg, M. (2007). The genealogy of lean production. Journal of Operations Management, 25(2), 420–437. https://doi.org/10.1016/j.jom.2006.04.001
Houghton, E., & Portougal, V. (1995). A planning model for just‐in‐time batch manufacturing. International Journal of Operations & Production Management, 15(9), 9–25. https://doi.org/10.1108/01443579510099625
Jain, R., & Lyons, A. C. (2009). The implementation of lean manufacturing in the UK food and drink industry. International Journal of Services and Operations Management, 5(4), 548. https://doi.org/10.1504/ijsom.2009.024584
James, T. (2006). Wholeness as well as leanness [lean production]. Manufacturing Engineer, 85(5), 14–17. https://doi.org/10.1049/me:20060502
Jayaram, J., Das, A., & Nicolae, M. (2010). Looking beyond the obvious: Unraveling the Toyota production system. International Journal of Production Economics, 128(1), 280–291. https://doi.org/10.1016/j.ijpe.2010.07.024
Jeanes, C. F. (1995). Achieving and exceeding customer satisfaction at Milliken. Managing Service Quality, 5(4), 6–11. https://doi.org/10.1108/09604529510796430
Lehtonen, J.-M., & Holmström, J. (1998). Is just‐in‐time applicable in paper industry logistics? Supply Chain Management: An International Journal, 3(1), 21–32. https://doi.org/10.1108/13598549810200906
Lyons, A. C., Vidamour, K., Jain, R., & Sutherland, M. (2013). Developing an understanding of lean thinking in process industries. Production Planning & Control, 24(6), 475–494. https://doi.org/10.1080/09537287.2011.633576
Malhotra, M. K., & Grover, V. (1998). An assessment of survey research in POM: from constructs to theory. Journal of Operations Management, 16(4), 407–425. https://doi.org/10.1016/s0272-6963(98)00021-7
Marksberry, P., Rammohan, R., & Vu, D. (2011). A systems study on standardised work: a Toyota perspective. International Journal of Productivity and Quality Management, 7(3), 287. https://doi.org/10.1504/ijpqm.2011.039349
Matar, A., & Eneizan, B. (2018). Determinants of financial performance in the industrial firms: Evidence from Jordan. Asian Journal of Agricultural Extension Economics & Sociology, 22(1), 1–10. https://doi.org/10.9734/ajaees/2018/37476
Melton, T. (2005). The benefits of lean manufacturing. Chemical Engineering Research & Design: Transactions of the Institution of Chemical Engineers, 83(6), 662–673. https://doi.org/10.1205/cherd.04351
Mukhopadhyay, S. K., Dwivedy, J., & Kumar, A. (1998). Design and implementation of an integrated production planning system for a pharmaceutical manufacturing concern in India. Production Planning & Control, 9(4), 391–402. https://doi.org/10.1080/095372898234127
Mumani, A. A., Magableh, G. M., & Mistarihi, M. Z. (2022). Decision making process in lean assessment and implementation: a review. Management Review Quarterly, 72(4), 1089–1128. https://doi.org/10.1007/s11301-021-00222-z
Nawanir, G., Kong Teong, L., & Norezam Othman, S. (2013). Impact of lean practices on operations performance and business performance: Some evidence from Indonesian manufacturing companies. Journal of Manufacturing Technology Management, 24(7), 1019–1050. https://doi.org/10.1108/jmtm-03-2012-0027
Oduoza, C. F. (2009). Strategy for capacity management of batch constrained heat treatment operations in the manufacture of multiproduct families. International Journal of Manufacturing Technology and Management, 16(4), 398. https://doi.org/10.1504/ijmtm.2009.023755
Palacios Gazules, S., Giménez Leal, G., & de Castro Vila, R. (2023). Longitudinal study of lean tools in Spanish manufacturing firms. Journal of Manufacturing Technology Management, 34(9), 64–83. https://doi.org/10.1108/jmtm-11-2022-0406
Pandey, V. C., Garg, S. K., & Shankar, R. (2010). Impact of information sharing on competitive strength of Indian manufacturing enterprises: An empirical study. Business Process Management Journal, 16(2), 226–243. https://doi.org/10.1108/14637151011035570
Panwar, A., Jain, R., & Rathore, A. P. S. (2015). Lean implementation in Indian process industries – some empirical evidence. Journal of Manufacturing Technology Management, 26(1), 131–160. https://doi.org/10.1108/jmtm-05-2013-0049
Panwar, A., Nepal, B. P., Jain, R., & Rathore, A. P. S. (2015). On the adoption of lean manufacturing principles in process industries. Production Planning & Control, 26(7), 564–587. https://doi.org/10.1080/09537287.2014.936532
Papadopoulou, T. C., & Özbayrak, M. (2005). Leanness: experiences from the journey to date. Journal of Manufacturing Technology Management, 16(7), 784–807. https://doi.org/10.1108/17410380510626196
Pavnaskar, S. J., Gershenson, J. K., & Jambekar, A. B. (2003). Classification scheme for lean manufacturing tools. International Journal of Production Research, 41(13), 3075–3090. https://doi.org/10.1080/0020754021000049817
Pettersen, J. (2009). Defining lean production: some conceptual and practical issues. The TQM Journal, 21(2), 127–142. https://doi.org/10.1108/17542730910938137
Powell, D., Alfnes, E., & Semini, M. (2010). The application of lean production control methods within a process-type industry: The case of hydro automotive structures. In IFIP Advances in Information and Communication Technology (pp. 243–250). Springer Berlin Heidelberg.
Ramakrishnan, V., Jayaprakash, J., Elanchezhian, C., & Vijaya Ramnath, B. (2019). Implementation of Lean Manufacturing in Indian SMEs-A case study. Materials Today: Proceedings, 16, 1244–1250. https://doi.org/10.1016/j.matpr.2019.05.221
Ramesh, S., & Mathivanan, N. (2009). Screening of marine actinomycetes isolated from the Bay of Bengal, India for antimicrobial activity and industrial enzymes. World Journal of Microbiology and Biotechnology, 25(12), 2103–2111.
Reyes, J. A. G., Parkar, H. S., Oraifige, I., Meier, H. S., & Harmanto, D. (2012). An empirical-exploratory study of the status of lean manufacturing in India. International Journal of Business Excellence, 5(4), 395. https://doi.org/10.1504/ijbex.2012.047906
Rubio, S., & Corominas, A. (2008). Optimal manufacturing–remanufacturing policies in a lean production environment. Computers & Industrial Engineering, 55(1), 234–242. https://doi.org/10.1016/j.cie.2007.12.009
Sadeghifam, A. N., Zahraee, S. M., Meynagh, M. M., & Kiani, I. (2015). Combined use of design of experiment and dynamic building simulation in assessment of energy efficiency in tropical residential buildings. Energy and Buildings, 86, 525–533. https://doi.org/10.1016/j.enbuild.2014.10.052
Sahay, B. S., Gupta, J. N. D., & Mohan, R. (2006). Managing supply chains for competitiveness: the Indian scenario. Supply Chain Management: An International Journal, 11(1), 15–24. https://doi.org/10.1108/13598540610642439
Sahoo, S. (2019). Lean manufacturing practices and performance: the role of social and technical factors. International Journal of Quality & Reliability Management, 37(5), 732–754. https://doi.org/10.1108/ijqrm-03-2019-0099
Saleh, M. A. (2015). Environmental Awareness and its Role in the Application of Environmental Accounting Disclosure in the Jordanian Industrial Companies. In Public Participation and its Impact on Investor Decisions in the Amman Financial Market.
Schonberger, R. J. (2007). Japanese production management: An evolution—With mixed success. Journal of Operations Management, 25(2), 403–419. https://doi.org/10.1016/j.jom.2006.04.003
Sebtaoui, F. E., Adri, A., & Rifai, S. (2020). Literature review on successful JIT implementation: benefits, obstacles and critical success factors. International Journal of Logistics Systems and Management, 37(2), 153. https://doi.org/10.1504/ijlsm.2020.110571
Seth, D., Seth, N., & Goel, D. (2008). Application of value stream mapping (VSM) for minimization of wastes in the processing side of supply chain of cottonseed oil industry in Indian context. Journal of Manufacturing Technology Management, 19(4), 529–550. https://doi.org/10.1108/17410380810869950
Shah, R., & Ward, P. T. (2003). Lean manufacturing: context, practice bundles, and performance. Journal of Operations Management, 21(2), 129–149. https://doi.org/10.1016/s0272-6963(02)00108-0
Shah, R., & Ward, P. T. (2007). Defining and developing measures of lean production. Journal of Operations Management, 25(4), 785–805. https://doi.org/10.1016/j.jom.2007.01.019
Shahpanah, A., Poursafary, S., Shariatmadari, S., Gholamkhasi, A., & Zahraee, S. M. (2014). Optimization waiting time at berthing area of port container terminal with hybrid Genetic algorithm (GA) and Artificial Neural Network (ANN). Advanced Materials Research, 902, 431–436. https://doi.org/10.4028/www.scientific.net/amr.902.431
Singh, B., Garg, S. K., & Sharma, S. K. (2010). Scope for lean implementation: a survey of 127 Indian industries. International Journal of Rapid Manufacturing, 1(3), 323. https://doi.org/10.1504/ijrapidm.2010.034253
Singh, B., Garg, S. K., Sharma, S. K., & Grewal, C. (2010). Lean implementation and its benefits to production industry. International Journal of Lean Six Sigma, 1(2), 157–168. https://doi.org/10.1108/20401461011049520
Srinivasaraghavan, J., & Allada, V. (2006). Application of mahalanobis distance as a lean assessment metric. The International Journal of Advanced Manufacturing Technology, 29(11–12), 1159–1168. https://doi.org/10.1007/s00170-005-0004-2
Subramani, R., & Narayanasamy, M. (2009). Screening of marine actinomycetes isolated from the Bay of Bengal, India for antimicrobial activity and industrial enzymes. World Journal of Microbiology and Biotechnology, 25(12), 2103–2111. https://doi.org/10.1007/s11274-009-0113-4
Tanudiharjo, R., Yun, F., Joo, J., & Arokiam, I. (2021). Investigation of factors impacting lean implementation in the Indonesian fast-moving consumer goods industry. Operations and Supply Chain Management an International Journal, 162–172. https://doi.org/10.31387/oscm0450294
Uday, R. M., Salman, S., Karim, M. R., Ar Salan, M. S., Islam, M., & Shahriar, M. (2023). Assessing the barriers to lean manufacturing adoption in the furniture industry of Bangladesh: a fuzzy-DEMATEL study. International Journal of Industrial Engineering and Operations Management. https://doi.org/10.1108/ijieom-07-2023-0060
Upasani, S. (2012). Emerging supply chain management practices in Indian manufacturing industries. International Journal of Research in IT & Management, 2(2), 1237–1248.
Wangwe, S., Mmari, D., Aikaeli, J., Rutatina, N., Mboghoina, T., & Kinyondo, A. (2014). The performance of the manufacturing sector in Tanzania: Challenges and the way forward.
Womack, J. P., Jones, D. T., & Roos, D. (2007). The machine that changed the world: The story of lean production--Toyota’s secret weapon in the global car wars that is now revolutionizing world industry. Simon and Schuster.
Wong, Y. C., Wong, K. Y., & Ali, A. (2009). A study on lean manufacturing implementation in the Malaysian electrical and electronics industry. European Journal of Scientific Research, 38(4), 521–535.
Wyrwicka, M. K., & Mrugalska, B. (2017). Mirages of lean manufacturing in practice. Procedia Engineering, 182, 780–785. https://doi.org/10.1016/j.proeng.2017.03.200
Zahraee, S. M. (2016). A survey on lean manufacturing implementation in a selected manufacturing industry in Iran. International Journal of Lean Six Sigma, 7(2), 136–148. https://doi.org/10.1108/ijlss-03-2015-0010
Zahraee, S. M., Golroudbary, S. R., Hashemi, A., Afshar, J., & Haghighi, M. (2014). Simulation of manufacturing production line based on arena. Advanced Materials Research, 933, 744–748. https://doi.org/10.4028/www.scientific.net/amr.933.744
Downloads
Published
Issue
Section
License
Copyright (c) 2024 South Asian Journal of Social Sciences and Humanities
This work is licensed under a Creative Commons Attribution 4.0 International License.