The growing gap between lean production and digital lean tools

Abstract

Purpose This paper aims to gain empirical insights into the relationship between lean production and digitalization within Industry 4.0 from a process-theoretical perspective. Following an initial report at the European Lean Educators Conference 2021 conference, the authors searched for explanations as to why digital lean tools stagnate, whereas production improves continuously. Design/methodology/approach This paper is based on a qualitative case study in a Norwegian processing industry company over a period of 18 months from 2020 to 2022. Findings Process theory offers explanations of why digitalization and lean can change over time. Despite agile development, digitalization is still characterized by centralization and programmatic planning. Lean production is decentralized, with long-term and continuous change processes. This creates challenges for coordination between digitalization and lean. Practical implications Organizations should strive for coordination and collaboration between central and local decision makers and between digital and business process competence. Digital systems should have built-in flexibility for local setup, and local managers need sufficient competence to set up systems that are aligned with continuous improved production. Originality/value This study contributes empirical insights into real-life industry challenges to a literature that has until now been theoretical and focused on potential synergies.

Integrating advanced digital technologies in existing lean-based production systems: analysis of paradoxes, imbalances and management strategies

“…However, there is a gap in research examining paradoxes arising from the attempts to integrate LP and digital technologies (e.g. Holmemo and Korsen, 2023). Hence, this paper aims to advance the understanding of tensions and their paradoxical relationship and potential strategies for manage tensions when integrating digital technologies into existing LPSs.…”

“…, 2021), e.g. the tensions between centralised digitalisation of processes vs. decentralised improvement work (Holmemo and Korsen, 2023. Tension in this context refers to conflicts or unease that arise when trying to harmonise disparate elements (Putnam et al.…”

Guest editorial: Lean and learning in the age of digitalization

“…McDermott (2023) also presents practical insights from converting classroom-based teaching of lean education to online delivery during COVID-19 and highlights the importance of using practical examples and problem-based learning for more effective realization of student learning outcomes. Holmemo and Korsen (2023) presents empirical insights into the relationship between lean production and digitalization from a process-theoretical perspective. The authors suggest that the centralized nature of digitalization initiatives is contradictory to the decentralized nature of lean production, which creates challenges for organizations.…”

“…Holmemo and Korsen (2023) presents empirical insights into the relationship between lean production and digitalization from a process–theoretical perspective. The authors suggest that the centralized nature of digitalization initiatives is contradictory to the decentralized nature of lean production, which creates challenges for organizations.…”

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“…This study shows the scarcity of research linking data science tools and techniques to lean production practices. Likewise, Holmemo and Korsen (2023) and Psomas (2021) have pointed out the lack of integration with data science, big data and Industry 4.0 concepts.…”