A strategic and operational approach to assess the lean performance in radial tyre manufacturing in India : A case based study

Purpose – The purpose of this study is to assess the lean performance of a tyre manufacturing firm in India. The key objective is to find key strategic and operational decision‐making dimensions for developing effective lean manufacturing environment in a tyre manufacturing organization. Design/methodology/approach – This research is empirical in nature where the opinions of a group of experts of an Indian tyre manufacturing firm were consulted to formulate an interpretive structural model (ISM) of the critical success factors of lean manufacturing implementation in a tyre manufacturing organization. The authors have developed an Excel‐based template for quantitative assessment of lean performance indicators on the basis of feedback from the operational staff. Findings – This research work suggests that financial capability of an organization drives the top‐management commitment for incorporating lean manufacturing practices in a tyre manufacturing organization. Organizational culture and human resource management are the important enablers for developing change management paradigm, which in turn leads to performance improvement. This study also reveals that over‐processing as well as excessive defects are the most detrimental wastes in radial tyre manufacturing, which accounts for high manufacturing cost of radial tyre manufacturing in India. Research limitations/implications – Since this study is carried out in a single (case) organization, a relatively small sample size restricts the outcome from being considered for generic industrial application. This study none the less is useful for practicing managers and academicians for the development of lean manufacturing strategy in context with the tyre industry since it encompasses insightful views of experienced lower to upper middle level managers. Originality/value – This paper provides some key enablers for the successful implementation of lean tools in Indian tyre manufacturing, where lean practices are still in the early stage and little literature is available in this context with tyre manufacturing. Also an attempt has been made to develop a simple Excel‐based template for lean assessment in the tyre industry. This template can be used in other industries by simply modifying the key attributes.