Assessing lean implementation and benefits within Indian automotive component manufacturing SMEs

Abstract

PurposeThe purpose of this paper is to investigate the status of lean manufacturing in Indian automotive sector, component manufacturing industries in terms of lean adoption, benefits, motivation, and challenges of implementing lean manufacturing practices.Design/methodology/approachThe research objectives were achieved by conducting a qualitative multicase study approach. Fourteen Indian automotive component manufacturing small and medium-sized enterprises (SMEs) were chosen based on their different product offerings as well as differing approaches to the introduction and implementation of lean initiatives. Data were collected through in-depth, semistructured interviews supported by shop-floor observations.FindingsThe findings from the present study suggest that some of the participating automotive component manufacturing SMEs have a relatively good understanding of lean concepts and philosophy. However, there is room for further improvement for most SMEs. Major top five lean practices being implemented were found to be cellular manufacturing, total productive maintenance, 5S, work standardization, and quality management practices. Also, leadership and organizational culture were found to be crucial factors for the success of lean manufacturing.Research limitations/implicationsThe fact that the data collected for the research study is based on subjective business evidence obtained from company representatives comprises the main limitation of the present study. So, the results should be considered with caution, as far as the lean adoption in Indian automotive component manufacturing sector is concerned.Practical implicationsBased on the present study, suggestions can be made regarding the successful adoption of lean principles, not only for the participating SMEs but also for the whole of the automotive component manufacturing sector. More specifically, by determining the strength and weakness of automotive component manufacturing SME's effort to adopt lean, suitable managerial initiatives can be undertaken by these companies as well as the whole sector to fully adopt lean and derive the respective benefits.Originality/valueThis paper explores the status of lean adoption in Indian automotive component manufacturing SMEs. Considering the unique characteristics of the automotive component manufacturing industry, the present research would be helpful for making strategies to implement lean in automotive component manufacturing industry setups.

Proposing a Supply Chain Collaboration Framework for Synchronous Flow Implementation in the Automotive Industry: A Moroccan Case Study

“…The automotive industry is becoming increasingly competitive due to, among others, the evolving nature of the products, the variety of models, and customer requirements. The tough competitiveness has pushed automotive manufacturers to revisit various established strategies and reassess their viability under the lean lens [1]. The implementation of lean practices aims at eliminating wastes and reducing inventory costs [2].…”

“…The implementation of lean practices aims at eliminating wastes and reducing inventory costs [2]. Lean tools applied in the automotive industry include, but are not limited to, cellular manufacturing, 5S, total productive maintenance, work standardization, quality management, visual control, statistical processes control, pull production, long-term relationships with suppliers, and synchronous flow [1]. Particularly synchronous flow in the automotive industry has gained importance with the increasing complexity and diversity of components and sub-assemblies that suppliers deliver to their contractors.…”

“…Numerous studies have shown the benefits of implementing lean practices in the automotive industry [1]. However, for a company, being lean is not sufficient to gain full competitive advantages, the company's suppliers are also required to pursue a lean strategy for better performance [4].…”

“…It focuses on continuous improvement through the elimination of non-added-value activities along the supply chain [4]. Thus, the lean methods, which are extensively applied in the automotive industry, need to be extended to the auto-component suppliers so that the whole supply chain becomes lean [1]. For that purpose, several authors have identified the collaboration with suppliers as the main factor for the successful implementation of lean tools and practices among the supply chain [6,7].…”

Cost-Benefit Models on Integrating Information Technology Services in Automotive Production Management

“…Under the guidance of the "Made in China 2025" action plan, the whole industry chain of automobile manufacturing will be deeply integrated and applied with the new-generation information technology. e automobile parts manufacturing enterprises will achieve the refined production, the automobile manufacturing enterprises will achieve the intelligent manufacturing, and the whole industry chain will achieve the real-time interconnection and intelligent logistics and jointly promote the transformation and upgrading of the automobile manufacturing industry [2].…”