Measuring parameters of lean manufacturing realization

Purpose – Manufacturing organizations are under pressure to improve productivity and reduce costs through the realization of lean manufacturing. This paper approaches lean manufacturing and aims to identify and measure the intimately associated parameters of lean manufacturing and also examines the weight of their contribution to overall lean manufacturing. Design/methodology/approach – A questionnaire survey study was performed in Indian manufacturing industries to collect data. The reliability of the survey instrument was pre‐tested and an acceptable value of Cronbach's α (a reliability coefficient) was found. Three experts determined the relative weight of various parameters using analytical hierarchy process (AHP). Pearson's coefficient of correlation analysis was used to measure the strength of the relationships between various parameters of lean manufacturing. Findings – The experts found “elimination of waste” to be the most important parameter of lean manufacturing, followed by “just in time deliveries”. The survey shows that most of the responding firms are in transition towards the realization of lean manufacturing. These firms believe that the factors that drive the realization of lean manufacturing are “just in time deliveries” and achieving “continuous improvement”. This study also revealed that Indian manufacturing industries are still overlooking the elimination of waste, the most important parameter of lean manufacturing. Research limitations/implications – The major limitation of this paper is the sample size ( n =52). Practical implications – The present study provides guidelines to assess the status of leanness in the manufacturing industries. According to conclusions, feeble areas in the manufacturing system can be identified and a suitable course of action might be planned for the improvement. Hopefully this study will help the firm's management to identify the problems to implement an effective lean manufacturing. Originality/value – In this work, the theoretical perspective was used not only to update the original instrument, but also to study the subject from a perspective beyond that usually associated with lean manufacturing.