Purpose The purpose of this paper is to propose an integrated performance measurement framework to measure the effect of lean implementation throughout all functions of an organization. Design/methodology/approach The paper identifies the seven categories representing all organizational functions. These categories have been divided into 26 performance dimensions and key performance indicators (KPIs) for each performance dimension have been identified to measure lean performance. The interrelationship of each category with lean principles and/or lean wastes has been identified. KPIs are developed on the basis of identified criteria, frequency analysis of existing literature, and discussion with industry professionals. Finally, an integrated performance measurement framework is proposed. Findings The proposed framework evaluates the organization under seven categories – manufacturing process, new product development (NPD), human resource management, finance, administration, customer management, and supplier management. In total, 26 dimensions and 119 key performance indicators have been identified under the seven categories. Research limitations/implications The proposed framework is a conceptual framework and it is to be tested by empirical and cross-sectional studies. Originality/value The main novelty of the research is that the leanness of the organization has been measured throughout the supply chain of the organization in an integrated way. The various areas of measurement are manufacturing process, NPD, finance, administration, customer management, and supplier management. Further, the proposed KPIs are also categorized as qualitative or quantitative, strategic or operational, social or technical, financial or non-financial, leading or lagging, static or dynamic. This paper contributes to the body of knowledge in performance measurement.

Purpose The purpose of this paper is to review various themes of leanness, leanness assessment approaches, leanness assessment areas, and their evolution by a systematic literature review (SLR). Design/methodology/approach The eight types of literature review methodologies are identified and compared. The SLR is selected after critically analyzing the eight types of literature reviews. A four-phased SLR (i.e. plan, do, analyze/synthesize, and propose) has been carried out based on the peer-reviewed journal and conference articles on leanness assessment. Findings The existing literature on leanness assessment shows the lack of review-based papers on lean assessment. This study attempts to build a two-fold contribution to the field of leanness assessment: first, various types of themes, approaches, and assessment areas are identified; second, a framework for leanness assessment is proposed. The study shows that the research on leanness assessment is mainly empirical using qualitative judgment. The paper traces the changes in scope, areas, and approaches to leanness assessment. The scope of leanness assessment broadened from manufacturing process assessment to whole supply chain assessment including manufacturing process. The focus of earlier assessment was manufacturing and financial areas which now includes human resource, administration, new product development, suppliers, and customers also. Tool and technique based assessment has given way to outcome-based assessment using non-financial and qualitative parameters. Research limitations/implications One of the limitations of the study is that literature search was mainly focused on peer-reviewed articles published in English language only; therefore, some papers in others languages may have been missed. Apart from this, the SLR has been conducted for the manufacturing sector only. Practical implications The study is expected to be useful for the lean practitioners to identify the causes of reported lean failures. Moreover, the authors also expect that the conducted SLR will provide the passage to the practitioners for not only fostering the concepts on leanness assessment but also provide the vital and significant knowledge about the leanness assessment to the managers for enhancing organizational performance. Originality/value As per the authors’ knowledge, this is the first SLR on leanness assessment. It is expected that this paper will help the researchers working in the area of lean manufacturing to identify new areas of research.

PurposeThe paper aims to identify, prioritize and rank lean practices in the context of an Indian automotive component manufacturing organization using interpretive ranking process (IRP) and interpretive structural modeling (ISM) approaches.Design/methodology/approachLean practices are identified from the literature. Then, two hierarchical models were are developed using two distinct modeling approaches – ISM and IRP with expert opinions from an Indian automotive component manufacturing organization to analyze the contextual relationships among the various lean practices and to prioritize and rank them with respect to performance dimensions.FindingsIn the study, the hierarchical structural models are developed using ISM and IRP approaches for an Indian automotive component manufacturing organization. In ISM-based modeling, lean practices can be categorized into five levels. Top priority should be given to the motivators followed by value chain, system/technology and organization centric practices. IRP model shows the dominance relationship among the various lean practices with respect to performance dimensions.Practical implicationsThe models are constructed from the organizational standpoint to evaluate their impact to the implementation of lean manufacturing. The study leverages the organizations to prioritize limited resources as per the hierarchy. Managers get the inter-linkages and ranking of various lean practices, which leads to a better perspective for the effective implementation of lean. The structural models also assist management to assign proper roles to employees/departments for effective lean implementation.Originality/valueThere is hardly any structural model of lean practices in the literature for clustering, prioritizing and ranking of lean practices. The study fills this gap and develops the hierarchical models of lean practices through IRP and ISM approaches for an Indian automotive component manufacturing organization. The results from both approaches are compared for illustrating the benefits of one over the other.

PurposeThis paper proposes an integrated value stream mapping (VSM) for a complex assembly line to improve the leanness of a complex automotive component manufacturing organization.Design/methodology/approachThis study depicts the application of VSM at the case organization, where top management is concerned about the challenges of higher cycle time and lower productivity. Gemba walks were conducted to establish the concept of “walk the flow, create the flow” along the assembly line. The multi-hierarchical cross-functional team developed the current value stream map to know the “as-is” state. Then, the team analysed the current VSM and proposed the future VSM for the “to-be” state.FindingsThe integrated VSM shows different processes and work cells, various wastes, non-value-added activities, cycle time, uptime and the material and information flows for both products of the assembly line on the same map. The integrated VSM reduced cycle time, non-value-added activities, work in process inventory and improved line efficiency and production per labour hour for both the products, simultaneously.Research limitations/implicationsThe limitation of the study is that the study focussed only on the application of VSM for one complex assembly only. Future research may be conducted using the developed integrated VSM approach in other complex production environments.Practical implicationsManagers can identify and reduce system waste by incorporating the concept of integrated VSM in a complex production or assembly environment where two or more products are being manufactured/assembled with low similarity.Originality/valueThe application of VSM for assembly lines is highly challenging because of merging flows, a large number of child parts in the lines and assembly of more than one product on the same line.

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