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Toward sustainable primary production through the application of lean management in South African fruit horticulture
Abstract
This paper aims to understand the relationship between patterns of lean practice implementation, farm size and sustainable performance among fruit horticultural primary producers in South Africa. Utilizing a comprehensive lean framework, addressing 10 lean practice dimensions, the authors collected data from a sample of 132 fruit farming operations in South Africa. First, cluster analysis was applied to identify distinct clusters of farms with common lean practice implementation characteristics. Next, the distinct clusters were tested to identify significant differences in lean practice implementation and sustainable performance, with farm size incorporate as a control variable. In terms of common lean implementation characteristics, the analysis identified two distinct clusters of farms, labelled as the high lean practice cluster and the low lean practice cluster. It is determined that these two clusters differ significantly in practice implementation across all 10 dimension of lean management practice. It is further established that the two clusters differ significantly in terms of sustainable performance. Furthermore, Farm size is found to significantly differentiate (i) lean practice implementation across 5 of the 10 lean practice dimensions and (ii) levels of sustainable performance between medium and large sized farms. This empirical analyses of lean practices and sustainable performance outcomes in the primary production domain represents a novel contribution to the existing literature on lean management and horticultural management.
... Instead, these studies analyzed the LM tool generally. Papers like Caicedo Solano et al. (2019Solano et al. ( , 2020; Cox & Chicksand (2005); Kurtz et al. (2014); Carson (2018); Pearce et al. (2021); and Satolo et al. (2016a) focused their research in understanding how the LM philosophy work out in the agriculture environment. These articles are more technical than practical. ...
... Despite technological efforts to shorten the production time of agricultural products and smooth the differences in production volumes during harvest and off-season periods, most agricultural production is still subject to less flexible production times and use of resources than those found in various industrial or even service sectors. Pearce et al. (2021) conducted a study on 132 fruit farms in South Africa to investigate the performance benefits of LM in primary horticultural fruit production. They identified the presence of two distinct groups of producers within the study population. ...
... A topic that has been gaining attention is the impacts of using LM on the environmental sustainability of farming activities, such as the studies by , Muñoz-Villamizar et al. (2019), Reis et al. (2018), and Pearce et al. (2021). These point out that the use of LM tools and techniques was beneficial in reducing the environmental impact that farming activities cause. ...
Lean manufacturing (LM) is a management philosophy focused on reducing waste while enhancing system productivity. Although its advancements have been more pronounced in the manufacturing sector, the benefits that LM are increasingly being recognized in other areas, including agriculture. Research on the application of LM in agriculture and livestock farming remains limited but has been gaining traction in recent years, as evidenced by the findings of this study. To contribute to the exploration of this emerging field, this article aims to map the current research landscape through a systematic literature review, supplemented by a content analysis. The SLR presented in this study had three main objectives: to identify which LM tools and techniques are most used in rural production, their benefits, and the elements that are central to their successful implementation. The research identified value stream mapping as the most widely used tool in rural production. The primary benefits observed were waste reduction and increased farm revenue. Successful implementation of LM in this context requires a five-step process, which is detailed in the paper. Resumo: O Lean Manufacturing (LM) é uma filosofia de gestão focada na redução de desperdícios enquanto aumenta a produtividade dos sistemas. Embora seus avanços tenham sido mais pronunciados no setor de manufatura, os benefícios do LM estão sendo cada vez mais reconhecidos em outras áreas, incluindo a agricultura. A pesquisa sobre a aplicação do LM na agricultura e na pecuária ainda é limitada, mas vem ganhando força nos últimos anos, conforme evidenciado pelos achados deste estudo. Com o objetivo de contribuir para a exploração deste campo emergente, este artigo visa mapear o panorama atual da pesquisa por meio de uma revisão sistemática da literatura, complementada por uma análise de conteúdo. A RSL apresentada neste estudo teve três objetivos principais: identificar quais ferramentas e técnicas de LM são mais comumente utilizadas na produção rural, avaliar seus benefícios e determinar os elementos-chave necessários para sua implementação bem-sucedida. A pesquisa identificou o mapeamento de fluxo de valor como a ferramenta mais amplamente utilizada na produção rural. Os principais benefícios observados foram a redução de desperdícios e o aumento da receita das propriedades. A implementação bem-sucedida do LM nesse contexto requer um processo em cinco etapas, que é detalhado no artigo. Lean manufacturing in agriculture… 2/23 Gestão & Produção, 31, e1924, 2024 Palavras-chave: Lean manufacturing; Mapeamento do fluxo de valor agrícola; Produção agrícola; Gestão agrícola; Revisão sistemática da literatura.
... Instead, these studies analyzed the LM tool generally. Papers like Caicedo Solano et al. (2019Solano et al. ( , 2020; Cox & Chicksand (2005); Kurtz et al. (2014); Carson (2018); Pearce et al. (2021); and Satolo et al. (2016a) focused their research in understanding how the LM philosophy work out in the agriculture environment. These articles are more technical than practical. ...
... Despite technological efforts to shorten the production time of agricultural products and smooth the differences in production volumes during harvest and off-season periods, most agricultural production is still subject to less flexible production times and use of resources than those found in various industrial or even service sectors. Pearce et al. (2021) conducted a study on 132 fruit farms in South Africa to investigate the performance benefits of LM in primary horticultural fruit production. They identified the presence of two distinct groups of producers within the study population. ...
... A topic that has been gaining attention is the impacts of using LM on the environmental sustainability of farming activities, such as the studies by , Muñoz-Villamizar et al. (2019), Reis et al. (2018), and Pearce et al. (2021). These point out that the use of LM tools and techniques was beneficial in reducing the environmental impact that farming activities cause. ...
Lean manufacturing (LM) is a management philosophy focused on reducing waste while enhancing system productivity. Although its advancements have been more pronounced in the manufacturing sector, the benefits that LM are increasingly being recognized in other areas, including agriculture. Research on the application of LM in agriculture and livestock farming remains limited but has been gaining traction in recent years, as evidenced by the findings of this study. To contribute to the exploration of this emerging field, this article aims to map the current research landscape through a systematic literature review, supplemented by a content analysis. The SLR presented in this study had three main objectives: to identify which LM tools and techniques are most used in rural production, their benefits, and the elements that are central to their successful implementation. The research identified value stream mapping as the most widely used tool in rural production. The primary benefits observed were waste reduction and increased farm revenue. Successful implementation of LM in this context requires a five-step process, which is detailed in the paper.
... Toward sustainable primary production through the application of lean management in South African fruit horticulture [15] Evaluation of 132 fruit horticulture farms on lean implementation practices to reduce process losses 1 Main subject from the qualitative analysis. ...
... [5] Applying mathematical modeling that reduced the production cost by approximately 59% to solve the planning of agricultural production systems in the stages of sowing, tillage maintenance, and banana harvest. [15] The implementation index of the ten lean dimensions proposed [69] was evaluated in 132 fruit farming operations in South Africa. A higher practice of lean concepts was found on 44 farms. 1 Main results of lean tools applied in agro-pastoral productions. ...
... Pearce et al. [15] presented a study with 132 fruit farming operations in South Africa, analyzing the level of implementation of lean practices. It was statistically segregated that 44 farms (33.33%) have a high level of implementation. ...
Agriculture must find new ways to reduce costs and increase efficiency to meet the rising demand for products, avoiding waste due to potential food scarcity. Through the systematic literature review methodology, this study analyzes and synthesizes the existing literature on lean manufacturing (LM) applied in agro-pastoral production, its impact on reduction in losses and waste, and productivity increases considering production function mechanism (PFM), connecting to a sustainability model based on triple bottom line (TBL). A comprehensive search strategy was used to identify relevant studies and critically evaluate them using pre-determined inclusion and exclusion criteria. The findings provide insights into LM applied in agro-pastoral production and inform future research in the field, highlighting the potential of using LM concepts by reducing losses and waste and increasing productivity. The potential for TBL impacts from application of lean concepts in agro-pastoral production suggests a tendency for growth in this area of research. A theoretical understanding of how lean tools and techniques can be applied to improve productivity and profitability in the agricultural sector is provided, as well as practical examples and recommendations for implementing lean practices in agricultural operations, aligning sustainability and LP tools and concepts.
... According to Lopes et al. [42], despite numerous successful applications in various sectors, the particular characteristics of the food sector may have led to resistance to changing companies' practices and the implementation of new management philosophies. For Pearce et al. [43], more recent studies highlight that rising food prices and increasingly limited agricultural production capacity are contributing to the renewal of processes in primary production, with an emphasis on sustainability. They also highlight the urgency in eliminating waste that is strongly aligned with the agricultural need to reduce operational waste, whether in the form of inefficient labor used, food waste, water, or energy [43]. ...
... For Pearce et al. [43], more recent studies highlight that rising food prices and increasingly limited agricultural production capacity are contributing to the renewal of processes in primary production, with an emphasis on sustainability. They also highlight the urgency in eliminating waste that is strongly aligned with the agricultural need to reduce operational waste, whether in the form of inefficient labor used, food waste, water, or energy [43]. Solano et al. [44], defend that the current conditions of agricultural production increasingly require an improvement of techniques and tools to improve the management quality and productivity in agriculture. ...
... The application of Lean tools in the food processing industry has not received the same level of attention compared to traditional manufacturing industries. However, in 2021, the same authors Pearce et al. [43], point out that rising food prices and increasingly limited agricultural production capacity are contributing to process renewal in primary production with an emphasis on sustainability. They also highlight the urgency in eliminating waste that is strongly aligned with the agricultural need to reduce operational waste, whether in the form of inefficient labor used, food waste, water, or energy [43]. ...
The organizations of horticultural producers and, particularly, those that deal with extremely perishable endogenous fruits, such as peaches and cherries, have a greater need to optimize production flows and processes. A particularity of the horticultural industry is the short shelf life of raw materials and the seasonality of products. In this paper, optimization techniques are used to improve the production flows and the management of cold storage and distribution in a fruit central. The application of Lean tools allowed reducing the cycle time by 4.37 min and the lead time by 7.10 min of the whole process, i.e., a reduction of 35.5% and 10.6% of the cycle time and lead time, respectively, excluding the cold conservation operation. The study shows that it is possible to reduce, or even eliminate, waste throughout the process, reduce unnecessary movement, adapt the layout, maximize workspace, and level stocks, as well as greater supplier involvement in a continuous improvement approach. This approach can be outlined as a good practice for the optimization of productive flows and management logistics that may benefit productivity, energy efficiency, human resources distribution, food quality, and reduce food waste.
... Estudios recientes en productividad y eficiencia en el sector agrícola han integrado sistemas de mejora de la calidad en los procesos de cultivo como un objetivo emergente destacándose la implementación Lean (Caicedo et al., 2019). Esta implementación se debe a su adaptabilidad para desarrollar soluciones de reducción de pérdida de alimentos (Chairany et al., 2022), las oportunidades de adopción de principios basados en la creación de valor (Fladkjaer & Pejstrup, 2018), la adaptabilidad de soluciones para la gestión de la fuerza laboral (Pearce et al., 2021), la mejora del rendimiento centrado en la velocidad, el flujo y el costo de un proceso (Bella et al., 2024), entre otros. En el sector agrícola la filosofía Lean concibe acciones de mejora a partir de la eliminación de muda generadas por las malas prácticas de gestión desde la etapa inicial de cultivo hasta la distribución de productos cosechados (Caicedo et al., 2020). ...
... (Espera) (Melin & Barth, 2020) Genérico (Suecia) Identificar con mayor precisión las muda que inhiben el flujo de materiales y de información mediante mapeo de flujo de valor. (Pearce et al., 2021) Frutas Horticultura (Sur Africa) Mejorar la rentabilidad operativa y la gestión de la fuerza laboral mediante prácticas lean. (Espera) (Chairany et al., 2022) Pimienta de Cayena (Indonesia) Reducir riesgos de pérdida de alimentos en cadenas de suministro agrícola mediante principios Lean (Espera, Inventario, Producto defectuoso). ...
Improvements in production systems that use the lean manufacturing approach known as “Lean” have the objective of eliminating or reducing waste or process inefficiencies (muda). This approach is increasingly adopted by different industrial sectors, including agriculture. Although Lean improvements are traditionally applied to existing processes from cultivation to distribution, opportunities to intervene in processing wastes (losses) are left aside. This article presents a methodological approach framed in five Lean principles, made up of six activities aimed at the design of new processes that make use of the losses generated by harvesting and agricultural transformation. The methodological approach is applied in a Colombian coffee farm where parchment coffee transformation processes are developed. A parallel losses composting process is designed that transforms defective, green, overripe beans, coffee pulp, mucilage and husk. The results show that by applying the methodological approach on the coffee farm, a level of losses transformation of 86% is achieved. Molting is also reduced for both the current parchment coffee production line and the composting line to 35% and 50% respectively. The main reductions are reprocessing and waiting times. Finally, a 30.3% reduction is obtained in the time of activities that do not add value, making both the current and proposed processes more efficient and with better delivery times.
... Evaluate the motives of SMEs to engage in agribusiness, and the perceived benefits and obstacles associated with adopting lean management; identified the type of quality cost incurred by Zalacca farmers and SMEs; and assesses the most feasible forms of lean practices by farmers Melin and Barth (2020) VSM Aim to increase understanding about lean implementation where value stream mapping (VSM) is used to create an action plan, on a small dairy and cattle farm in southwest Sweden Baca-Nomberto et al. (2021) Kaizen Examine the rice industry, with LM tools to improve quality, increase productivity, reduce inventories, and costs, such as the Kaizen method Pearce et al. (2021) None specifically Aim to understand the relationship between lean practice implementation patterns, farm size, and sustainable performance among primary horticultural fruit producers in South Africa Source: prepared by the authors Content courtesy of Springer Nature, terms of use apply. Rights reserved. ...
Lean Manufacturing (LM) is a notorious approach for increasing productivity in manufacturing industry. However, there is a great potential for using its tools and principles in other economic sectors, among which the agricultural sector stands out. Seeking to contribute to exploring this potential, this article proposes an adaptation of the Value Stream Mapping (VSM) tool for the agricultural context. A case study conducted on a coffee farm was used to validate the adaptations. Graphical presentations of the Current and Future State Maps proposed are presented. The paper demonstrates that the VSM is a valuable tool for rural managers because it is simple to understand and use. It also has important potential gains for the process, like increased productivity and competitiveness of agricultural production. The paper also makes novel theoretical propositions for adapting VSM to agricultural production conditions.
... Lean is a management philosophy and a continuous improvement approach that aims to identify Non-value-added (NVA) tasks and waste activities and to eliminate or minimise these activities (Soliman and Saurin, 2017;Pearce et al., 2021). Originating from the Toyota Production System (TPS), lean manufacturing has been in practice worldwide for the last 40 years, which can save up to fifty per cent of the investment by using not as much of every resource as the traditional mass production system (Bhasin, 2015). ...
Purpose
Bangladesh's ready-made garment (RMG) industry plays a vital role in the economic growth of this country. As the global trend in the fashion market has introduced a high-mix, low-volume ordering style, manufacturers are facing an increased number of changeovers in their production systems. However, most of the Bangladeshi RMG manufacturers are not yet ready to respond to such small orders and to improve the flexibility of their production systems. Consequently, the industry is falling behind in global market competition. Thus, this study aims to advance the current performance of RMG manufacturing operations to respond to the fast-fashion industry's challenges effectively using quick changeover.
Design/methodology/approach
In this study, a Single-Minute Exchange of Dies (SMED) is applied to attain quick changeover following the best practices of lean manufacturing.
Findings
This study examined the performance of the SMED technique to reduce changeover time in two case organisations. The changeover time was reduced by 70.76% from 434.56 min to 127.08 min and 42.12% from 2,664 min to 1,542 min for the case organisations, respectively. The results of this study show that companies require improved changeover times to address the demand for high-mix, low-volume orders.
Originality/value
This study will certainly guide practitioners of the RMG industry to adopt SMED to reduce changeover time to meet small batch production.
... Over the years, there has been a noticeable surge in research focusing on lean practices within the agri-food industry. This increasing trend can be attributed to the growing recognition of the importance of waste reduction and the expanding population within the agri-food supply chain [43], [44]. However, limited research has provided tangible evidence of the actual impact resulting from the implementation of lean practices [45] with few exceptions such as output projections derived from modelingbased [46]. ...
This thesis explores the integration of Lean Management principles into the ship recycling process to promote sustainability within the framework of the circular economy. Ship recycling, while vital for the maritime industry's operational cycle, poses significant environmental and social challenges. In response, this study explores the ways in which Lean Management approaches might improve sustainable ship recycling operations, establish a set of standard operating procedures, boost resource efficiency, and encourage environmental sustainability.
The research employs qualitative analysis methodology. Qualitative methods include interviews with industry experts, stakeholders, and policymakers to understand current practices, challenges, and opportunities in ship recycling. The findings highlight the potential of Lean Management techniques, such as value stream mapping, continuous improvement, and just-in-time inventory, to streamline ship recycling processes and mitigate environmental impacts. By identifying and eliminating non-value-added activities, Lean methodologies can enhance operational efficiency while minimizing resource consumption and pollution. Furthermore, the study examines the implications of Lean Management for social sustainability, including worker safety, labor conditions, and community engagement in ship recycling regions. By fostering a culture of continuous improvement and employee empowerment, Lean practices can contribute to creating safer and more equitable working environments in ship recycling yards. The research also addresses policy implications and industry best practices for integrating Lean Management into sustainable ship recycling initiatives. Recommendations are provided for policymakers, industry stakeholders, and practitioners to promote the adoption of Lean principles and drive positive environmental and social outcomes in the ship recycling sector.
Overall, by highlighting the potential of Lean Management techniques to improve environmental stewardship, operational efficiency, and social responsibility within the circular economy paradigm, this thesis adds to the
Adequate quality procedures in a citrus packhouse assist in decision-making to enable optimal value-add to the business. Citrus accounts for more than a third of the total fruit production in South Africa, and it also accounts for half of total fruit export revenue. Citrus production is affected by a variety of factors, including the following but not limited to entomological, climatological, grading, and physiological factors. This study aims to investigate the existing literature on quality procedures within an agricultural packhouse. The categories investigated in this study include different quality systems and their implementations within the agricultural industry. This paper will contribute to research by identifying the potential research gap in agricultural quality procedures.
The lean philosophy has long since moved from manufacturing plants to other operations such as insurance and healthcare. The agriculture industry is no different in terms of production processes, facilities, people, and challenges. However, agriculture provides a different set of challenges due to seasonal variability, bulk production, processing and problems in handling and storage. An opportunity exists to introduce the Lean concepts in more depth in agriculture given the magnitude of waste and losses in this industry. Therefore, the aim of this study is to conduct a rapid literature review in order to retrieve available research on Lean implementation in the agriculture industry to direct future research. The study identified one hundred and two studies highlighting the different applications of Lean-Agri. Given the increase in publication over the years, it is evident that research into Lean-Agri is increasing but more research is needed to further highlight its value and its range of applications.
Over the last few years, the Lean 4.0 concept has emerged and gained prominence
on the world stage for waste and efficient natural resources management,
once including the Lean thinking philosophy for management and
technologies from Industry 4.0 for supporting and sharing data and information
among the actors in the supply chain. This new management technic
allows reorganizes the business process and stimulates the circular supply
chain based on intelligent services and sharing data, information and knowhow
among the actors in production systems. However, it is not clear in the
current literature that the opportunities are linked to the relationship between
Lean 4.0 and the efficient use of resources in the agro-industrial environment.
Based on the exposure, this paper intends to show an agenda for future
research linked to Lean 4.0 in the value co-creation in agro-industrial services.
We identified five topics for future research that are related to Lean 4.0 for efficient
resource use.
The concentration of carbon dioxide in the atmosphere continues to rise and the global food system is a significant contributor that often gets overlooked when it comes to solving the problem. In this study, emissions related to food transportation were studied to determine what impact getting local food instead of non-local food could make on the overall emissions of the food system. The dining service at University utilizes local food to varying extents when it is in season, and a life cycle assessment (LCA) was done on lettuce, tomatoes, strawberries, and chicken to compare the emissions associated with production of these foods. The transport-oriented GREET software was used for the LCA along with information from the sustainability coordinator at the university itself to get results. Given a lack of publicly available data regarding crop cultivation in certain areas of the U.S. some information had to be obtained from databases in Europe, but results suggest that produce coming from the west coast to the Virginia campus can have four to five times the emissions associated with production and produce from Florida can have roughly twice as many emissions associated with production. There is a relatively low number of LCAs done in America to compare this data to but it somewhat fits in with many European studies. Some LCAs do not factor in transportation processes but my results suggest that any American studies should factor in transportation since they can contribute greatly to the overall footprint of products. The current available software for LCAs lack consistency between programs, all having different strengths and weaknesses, and needs to be improved for quality results in the future.
There have been many literature reviews carried out on Lean implementation (LI) in larger organisations with specific focus on the automobile industry. Lean implementation among Small and Medium Enterprises (SMEs) has not been so extensively researched. This paper attempts to bridge this gap by reviewing the literature that discussed Lean implementation in SMEs with a perspective of identifying the main challenges faced. We applied the Systematic Review Methodology proposed by Tranfield et al. (2003). This methodology allows for more comprehensive and profounder analysis along three stages: planning, conducting, and reporting. For this study, 403 papers were utilized, with their titles, abstracts and keywords separately studied at early stages of the review. These were collated from specific databases that included: ABI/INFORM Global, Taylor & Francis, Emerald, Sage, Inderscince, BSCO Business Source Premier, ScienceDirect and Scopus. The collected information was classified into four categories for more synthesis. The aim of this study is to establish the current position of global understanding of Lean implementation in SME's, including examining the main categories of Lean im- plementation in the context of SMEs. Next, an inclusive discussion of associated Critical Success Factors (CSFs) for Lean implementation within SME's is established that can be used as guide for SME's owners and managers. Suggestions for future research orientations are thus provided.
Export horticulture in Kenya viewed as an agro-industrial food system is currently the fastest growing agricultural sub-sector in terms of foreign exchange earnings. Increased demand for horticulture products led to production spreading beyond the traditional mountainous high yielding areas into arid and semi-arid zones as in Northwest Mount Kenya. This food system competes with other food systems for common pool resources needed for the production of food. We argue that local actors, especially poorer households lack the power to influence the institutions (‘rules of the game’) of production and resource ownership by which the dominant agro-industrial system impacts their livelihoods.
This paper is structured to include the following sections: the introduction, materials and methods, results, discussion and conclusions on the challenges and opportunities in export horticulture as an agro-industrial food system: Case study of Northwest Mount Kenya region.
The purpose of this article is to present and test a framework for lean implementation in the agricultural sector, addressing challenges from an operational and strategical perspective. The article builds on the previous literature on the use of Lean and reports empirical data from a lean implementation project in the south-western Sweden, including interviews, observations, diaries and questionnaires. A framework is developed to examine strategic and operational perspectives on Lean Thinking. Using this framework, a number of challenges encountered in Lean implementation are presented. This article is limited to the study of Lean among a group of Swedish farms although its findings may have implications for the wider agricultural sectors. Many societal challenges are linked with agricultural sustainability, stressing the need for productive, resource-efficient, resilient and less wasteful food production. This article is the first to develop and test a Lean implementation framework in the agriculture sector.
Purpose – The purpose of this paper is to delineates workers’ labour turnover and considerations around work, in a context of informalisation of work, through a case study of temporary non-resident farm workers in the deciduous fruit sector in Ceres, South Africa.
Design/methodology/approach – The research design is a three-phase exploratory sequential mixed-methods strategy. Findings from 29 in-depth interviews were refined, verified and ranked in four focus groups. These informed grounded indicators in a survey of 200 farm workers employed in peak season and their 887 household members.
Findings – Considerations are informed by work-related insecurities, interpersonal workplace relationships and reproductive insecurity in the form of care of others, social linkages and residential insecurity, seemingly hierarchical. The least important considerations most thwart workers’ ability to complete fixed-term contracts and account for over 70 per cent of labour turnover in the form of resignations. In sum, workers experience constrained considerations around work arising from their material, social and economic conditions.
Originality/value – This is the first study on the labour turnover of farm workers in South Africa and the fifth globally. The research gives precedence to the voice of farm workers and is a thick description of workers’ considerations around work.
Questionnaires are a widely used research method in human resource management (HRM), and multi-item psychometric scales are the most widely used measures in questionnaires. These scales each have multiple items to measure a construct in a reliable and valid manner. However, using this method effectively involves complex procedures that are frequently misunderstood or unknown. Although there are existing methodological texts addressing this topic, few are exhaustive and they often omit essential practical information. The current article therefore aims to provide a detailed and comprehensive guide to the use of multi-item psychometric scales for HRM research and practice, including their structure, development, use, administration, and data preparation.
http://dx.doi.org/10.1002/hrm.21852
This paper introduces a literature review of 83 studies dealing with the degree of adoption of lean manufacturing practices around the world, and the links between those practices and organisation performance. The results of this study revealed that lean practices application still occurs in a fragmented way, disregarding the systemic linkage that is essential to lean manufacturing. Forty-one articles have suggested a positive effect of lean practices in at least one operational, financial and/or environmental performance metric. Nevertheless, five studies indicated that some lean practices had a negative effect on operational or financial performance. High demand variability, a perceived result of long-term lean manufacturing implementation, a country/company’s organisational culture and the difficulty of traditional costing production systems to measure and compare investments and economic gains from adopting lean manufacturing over time are some of the reasons to explain that negative effect of lean practice on performance.
Purpose
This paper aims to understand the patterns of lean production implementation, and the relationship between three context factors (i.e. firm size, positions within the supply chain and time length of the lean initiative) and the adoption of lean production practices in firms of the automotive supply chain in Brazil.
Design/methodology/approach
The authors collected data from 65 companies of the automotive supply chain in Brazil. For data analysis, first a cluster analysis was performed to identify common characteristics in the companies’ context factors when considering patterns of lean implementation. Then, multivariate analysis of variance was used to investigate the differences between the context factors and the degree of use of lean practices.
Findings
High lean adopters had better performance than low lean adopters in terms of lead time, inventory and turnover. Firms at the first and second tier of the automotive supply chain were “leaner” than firms at the third tier. Large-sized firms were more likely to have a higher degree of use of lean practices than medium and smaller ones. Some, but not all, lean practices followed these patterns. Results also showed that some lean practices were most commonly adopted at the beginning of the lean journey, whereas others took more time to mature.
Originality/value
This paper demonstrated how lean practices were implemented at different positions within the supply chain, and the patterns of implementation often followed. It also considers lean in the context of developing countries such as Brazil.
Reflections on Context in Service Research
Abstract
This article examines the nature of context and its implications for theory and research in service. It is a conceptual paper based on exploring existing research and theory related to context in service research. The paper shows how the characteristics of service make context both important and challenging. There is immense contextual diversity in service research as reflected for example in ecosystems made up of multiple contextual variables. There is a need to identify the context specific nature of middle range theory and the contextual logic of general theory. We explore the challenges of context for service theory and examine how we might learn from theory in a particular context and test or adapt it in other contexts.
Value: The findings of this paper are of value to researchers seeking to develop and justify theory in service research, (general, middle range or theory in use).
According to portfolio managers, agriculture in general, and farmland in particular, can be considered an emerging asset class. Specialized financial vehicles, such as private equity and mutual funds, are emerging and competing to attract potential investment in this asset class. In recent years, there has been significant development of such vehicles targeting South Africa’s farming sector. These innovations are led by a group of market intermediaries (e.g. asset managers or consultants) who endeavour to “re-shape” South African farmland as an opportunity for institutional investors. These “pioneers” engage in a multifaceted mediation process between global financial investors on one hand, and the South African agricultural sector on the other. Drawing upon an empirical study of such intermediaries in South Africa, this paper analyses the concrete mechanisms that facilitate this particular form of commodification. The paper presents and compares the intermediaries, giving particular attention to their structure, governance mechanisms and asset allocations within this “market in the making”. It describes how intermediaries develop different paths of asset valorization to unlock the “financial value” of South African farmlands (i.e. “liquifying”, standardizing, neutralizing, and depoliticizing agriculture as an asset). But, it also highlights some of the difficulties faced in the process of translating between international investors and local managers, questioning the “land-asset fiction” that is materializing through the subordination of farmland to the needs of financial society.
Current industrial production is driven by increasing globalization, which has led to a steady increase in production volumes and complexity of products aimed at the pursuit of meeting the needs of customers. In this context, one of the main tools in the management of customer value is Lean Manufacturing or Production, though it is considered primarily as a set of tools to reduce the total cost of the resources needed to achieve such needs. This philosophy has recently been enriched in the literature with case studies that link Lean Management (LM) with the improvement of environmental sustainability. The consequence is an expansion of the Computer Integrated Manufacturing (CIM); indeed, CIM, currently, combining and integrating the key business functions (e.g., business, engineering, manufacturing, and information management) with a view of the life cycle, does not highlight the strategic role of the environmental aspects. In order to deal with the increasingly rapid environmental degradation that is reflected in society, in terms of both economy and quality of life, Industrial Ecology (IE) introduced a new paradigm of principles and instruments of analysis and decision support (e.g., Life Cycle AssessmentLCA, Social Life Cycle Assessment -SLCA, Material Flow AccountMFA, etc.) that can be considered as the main basis for integrating the environmental aspects in each strategy, design, production, final product, and end of life management, through the re-engineering of processes and activities towards the development of an eco-industrial system. This paper presents the preliminary observations based on a analysis of both theories (LM-IE) and provides a possible assessment of the key factors relevant to their integration in a lean environmental management, highlighting both positives (lights) and possible barriers (shadows).
This article presents an in-depth bibliographic study about the creation, principles, evolution, and practices of the lean philosophy oriented to the services sector. More than 70 papers about “lean thinking” – specially with focus on services – have been carefully reviewed. It presents the principles of lean service in an organized way, companies applying lean service, and best practices and tools in the implementation of lean service. It shows that lean service does not have a single or specific model of tools, practices or standards. In fact, it is a mix of tools and practices that must be applied according the situation found to be improved. Despite the lack of a standards and methodology for use in services, its best practices, inherited from manufacturing, when applied to services can generate large economic and financial results, as well as improvement of workers’ behavior. But, like any change process, this study shows that the application of lean in services also suffers resistance. There might be limitations when evaluating lean practices and principles to services, specially those that have not yet been well defined and reported. Other limitations are due to the scarce articles in the literature. However, this research showed that the use of the lean philosophy in services proved to be effective and quite worthwhile. Several cases analyzed presented significant gains and confirmed an increasing and promising future for service companies “thinking lean”.
Purpose
The purpose of this paper is to develop and empirically validate an instrument containing operational measures of lean service. The instrument is intended for use by both researchers and practitioners.
Design/methodology/approach
The instrument was developed and validated in an iterative process between theoretical and empirical insights. Drawing on a wide selection of frequently cited papers on lean service, a preliminary list of items was generated. These items were then vetted through four steps in order to achieve high validity. Empirical refinement and validation included workshops and semi‐structured interviews with expert practitioners, as well as testing the instrument's ability to discriminate between high and low adoption of lean and portray changes during lean service adoption.
Findings
The instrument contains 34 items that assess enablers of lean adoption, lean practices, and operational performance. Empirical validation suggested the instrument was able to discriminate between high and low adoption of lean service, as well as portray changes over time during lean adoption.
Practical implications
Practicing managers will be able to use the instrument in order to track progress during lean service adoption, thereby identifying and acting upon deviations from planned progress.
Originality/value
The paper represents the first comprehensive attempt to develop an instrument for assessing lean service adoption. Through this instrument, operational definitions of lean service will allow researchers to measure the level of lean service adoption, and using this information, to develop knowledge of for instance the contingencies to lean service adoption, the problems and pitfalls in lean service adoption and the feasibility of transferring practices to various service settings.
The increasing use of lean production (LP) by companies from several sectors has substantially increased the amount of publications and different emphases on the subject, which amplifies the need for organisation of that knowledge. This article aims to identify the research areas on LP implementation and to propose research opportunities. The literature review was based on 102 studies published in the years between 1996 and 2012. The studies were divided into six research areas, named: (a) structure and scope of LP systems; (b) factors that influence in the LP implementation; (c) methods for implementing LP systems; (d) LP assessment methods; (e) results of implementing LP systems; and (f) adaptation of LP to particular sectors. The findings suggested that the substantial increase on the amount of publications on LP implementation has created fragmented and dissociated areas that would benefit from integration.
Intensive livestock farming has raised issues about environmental impacts and food security during the past 20 years. As a consequence, there is a strong social demand for sustainable livestock systems. Sustainable livestock systems should indeed be environmentally friendly, economically viable for farmers, and socially acceptable, notably for animal welfare. For that goal, many sustainability indicators and methods have been developed at the farm level. The main challenge is using a transparent selection process to avoid assessment subjectivity. Here, we review typologies of sustainability indicators. We set guidelines for selecting indicators in a data-driven context, by reviewing selection criteria and discussing methodological issues. A case study is presented. The selected set of indicators mainly includes (1) environmental indicators focusing on farmer practices; (2) quantitative economic indicators; and (3) quantitative social indicators with a low degree of aggregation. The selection of indicators should consider (1) contextualization to determine purpose, scales, and stakeholders involved in the assessment; (2) the comparison of indicators based on various criteria, mainly data availability; and (3) the selection of a minimal, consistent, and sufficient set of indicators. Finally, we discuss the following issues: topics for which no indicators are measurable from available data should explicitly be mentioned in the results. A combination of means-based indicators could be used to assess a theme, but redundancy must be avoided. The unit used to express indicators influences the results and has therefore to be taken into account during interpretation. To compare farms from indicators, the influence of the structure on indicator values has to be carefully studied.
Establishing predictive validity of measures is a major concern in marketing research. This paper investigates the conditions favoring the use of single items versus multi-item scales in terms of predictive validity. A series of complementary studies reveals that the predictive validity of single items varies considerably across different (concrete) constructs and stimuli objects. In an attempt to explain the observed instability, a comprehensive simulation study is conducted aimed at identifying the influence of different factors on the predictive validity of single versus multi-item measures. These include the average inter-item correlations in the predictor and criterion constructs, the number of items measuring these constructs, as well as the correlation patterns of multiple and single items between the predictor and criterion constructs. The simulation results show that, under most conditions typically encountered in practical applications, multi-item scales clearly outperform single items in terms of predictive validity. Only under very specific conditions do single items perform equally well as multi-item scales. Therefore, the use of single-item measures in empirical research should be approached with caution, and the use of such measures should be limited to special circumstances.
Purpose
This paper aims to assess the findings of a research project that investigates the scope for lean strategies to be adopted in beef, lamb and pig supply chains.
Design/methodology/approach
The paper reports on action research carried out in three red meat supply chains. The methodology is inductive and qualitative, using a multi‐case, multi‐site approach. Each of the supply chains was analysed from farm gate to consumer, interviewing multiple participants at each stage of the supply chain.
Findings
The analysis demonstrates that, although a lean approach has been introduced in the pig supply chain, it is much more problematic in beef and lamb supply chains. Furthermore, the majority of participants in the UK pig supply chain – the first to adopt lean strategies – have not received the commercial improvement (the “ stairway to heaven” of higher returns) that was anticipated. On the contrary, the majority of participants in this supply chain are experiencing a strategic “treadmill to oblivion” of continuous lean operational efficiency, but with low commercial returns.
Research limitations/implications
The research is based upon three red meat supply chains – beef, lamb and pig. It would be beneficial if further in‐depth studies could be undertaken in other agri‐food supply chains to further validate the findings.
Practical implications
If government agencies and/or multiple retailers develop lean strategies in UK beef and lamb supply chains, it is not at all clear that this will benefit all parties in these chains. This raises important questions about the efficacy and appropriateness of lean strategies in supply chains that do not have the same demand, supply and power and leverage characteristics as those in which lean principles were first developed.
Originality/value
This paper should be of value to researchers in this area and to managers responsible for strategy formation in UK agri‐food supply chains.
Purpose – The authors perform a large-scale literature review and use conceptual theory building to introduce the concept of sustainability to the field of supply chain management and demonstrate the relationships among environmental, social, and economic performance within a supply chain management context. Design/methodology/approach – Conceptual theory building is used to develop a framework and propositions representing a middle theory of sustainable supply chain management (SSCM). Findings – The authors introduce the concept of sustainability – the integration of environmental, social, and economic criteria that allow an organization to achieve long-term economic viability – to the logistics literature, and position sustainability within the broader rubric of SSCM. They then present a framework of SSCM and develop research propositions based on resource dependence theory, transaction cost economics, population ecology, and the resource-based view of the firm. The authors conclude by discussing managerial implications and future research directions, including the further development and testing of the framework's propositions. Originality/value – This paper provides a comprehensive review of the sustainability literature, introduces sustainability to the field of supply chain management, and expands the conceptualization of sustainability beyond the triple bottom line to consider key supporting facets which are posited to be requisites to implementing SSCM practices. The use of conceptual theory building to develop theoretically based propositions moves the concept of sustainability from a relatively a-theoretical treatment toward new theory in supply chain management.
After 20 years of neglect by international donors, agriculture is now again in the headlines because higher food prices are increasing food insecurity and poverty. In the coming years it will be essential to increase food productivity and production in developing countries, especially in Sub-Saharan Africa and with smallholders. This however requires finding viable solutions to a number of complex technical, institutional and policy issues including land markets, research on seeds and inputs; agricultural extension; credit; rural infrastructure; storage; connection to markets; rural nonfarm employment and food price stabilization. This paper reviews what the economic literature has to say on these topics. It discusses in turn the role played by agriculture in the development process and the interactions between agriculture and other economic sectors; the determinants of the Green Revolution and discuss the foundations of agricultural growth; issues of income diversification by farmers; approaches to rural development; and finally issues of international trade policy and food security which are at the root of the crisis in agricultural commodity volatility in the past few years.
This article discusses the strengths and weaknesses of lean management thinking in the food and farming industry in the UK. Based on a case study of red meat supply it is argued that the adoption of lean practices internally may be appropriate for all participants in the industry, but the inter-organisational aspects of lean may not be easy to apply in practice, nor appropriate, for many participants. For some participants -- especially the multiple retailers -- the adoption of lean principles may lead to a positive outcome with stable and/or increasing profitability. For the majority of participants in these industry supply chains, however, the adoption of lean principles may result in a high level of dependency on buyers and to low or declining levels of profitability.
Our research addresses the confusion and inconsistency associated with “lean production.” We attempt to clarify the semantic confusion surrounding lean production by conducting an extensive literature review using a historical evolutionary perspective in tracing its main components. We identify a key set of measurement items by charting the linkages between measurement instruments that have been used to measure its various components from the past literature, and using a rigorous, two-stage empirical method and data from a large set of manufacturing firms, we narrow the list of items selected to represent lean production to 48 items, empirically identifying 10 underlying components. In doing so, we map the operational space corresponding to conceptual space surrounding lean production. Configuration theory provides the theoretical underpinnings and helps to explain the synergistic relationships among its underlying components.
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This book contains seven case studies of global value chains as well as a discussion of the theory behind these chains. Specifically, it examines the impact of global value chains on local upgrading strategies, as well as the role of governments, buyers, donors, and civil society in influencing value chains and the importance of partnerships as mechanisms for value chain upgrading. An impressive group of eminent scholars deliver a thorough examination of this important economic and political phenomenon.
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The goal of lean production is to save costs, produce products in various quantities and cancel out all kind of wastes. The lean production system, developed as an alternative to the Western style production system, also takes place in the literature as an alternative application of traditional production systems. In this context, the main purpose of this study is to determine the feasibility and awareness of the lean production concept, which is widely accepted and applied in various sectors especially in developed countries, in Turkey. Within the framework of this purpose, the barriers that businesses face in lean production awareness and lean production practices have been measured on the sample of textile companies operating in Gaziantep province. Within the scope of the study, questionnaires were sent to 150 textile companies and 52 responses were received. As a result of the analysis, it was found out that most of the enterprises are not fully informed about lean production and their awareness of this production approach is at a medium level. Besides, it was determined that lean production practices differ according to the scale and capital structures of enterprises and market structures in which they operate.
The goal of lean production is to save costs, produce products in various quantities, and cancel out all kinds of wastes. The lean production system, developed as an alternative to the western style production system, also takes place in the literature as an alternative application of traditional production systems. In this context, the main purpose of this study is to determine the feasibility and awareness of the lean production concept, which is widely accepted and applied in various sectors especially in developed countries, in Turkey. Within the framework of this purpose, the barriers that businesses face in lean production awareness and lean production practices have been measured on the sample of textile companies operating in Gaziantep province. Within the scope of the study, questionnaires were sent to 150 textile companies and 52 responses were received. As a result of the analysis, it was found out that most of the enterprises are not fully informed about lean production and their awareness of this production approach is at a medium level. Besides, it was determined that lean production practices differ according to the scale and capital structures of enterprises and market structures in which they operate.
Farm size plays a critical role in agricultural sustainability. This may have far-reaching consequences for the economic and environmental performance of agricultural production, resulting, for instance, in an excessive use of mineral fertilizers. However, the magnitude of such effects and their main causes are not well understood, while being essential for effective policy development, especially for countries like China where the agricultural sector is still largely dominated by smallholder farms. In this paper, we review the current understanding of how farm size affects agricultural sustainability using China's crop farming as an example from economic, environment and social aspects. We analyze impacts from both a Chinese and a global perspective to identify intervention points to improve agricultural performance. We found that increasing farm size has a positive impact on farmer's net profit, as well as economic, technical and labor efficiency with mean coefficients of 0.005, 0.02 and 2.25, respectively. Nevertheless, the relationships between farm size and overall productivity, total factor productivity and allocative efficiency are still not well understood and therefore require more research. Meanwhile, increase in farm size is associated with statistically significant decrease in fertilizer and pesticide use per hectare, showing clear benefits for environmental protection. In line with the experiences documented for the evolution of agricultural practices in developed countries, the expansion of large-scale farming is a critical path for modernizing agricultural production and ensuring sustainable food production from the social perspective. Measures concerning farm size should be implemented in an interaction between farmers and the government to promote the green development of agriculture.
Increased global competition in the agricultural sector is rapidly changing the structure of farms and farming. As the number of small and diversified farms (often family-owned) decreases, the number of large and specialized farms (often corporate-owned) is increasing. In this transformation, the agricultural sector is more and more concerned with strategy, innovation, and competition in the effort to be more productive and more profitable. At the same time, the sector faces demands that it become more environmentally responsible in its policies and practices. This paper proposes a Lean Implementation Framework that small and mid-size farms can use as they aim to increase production and profit and yet support environmental sustainability. This case study takes an action-oriented research approach that focuses on the implementation of a Green Lean approach at 34 Swedish farms using various Lean tools. The paper describes how training sessions, farm visits, workshops, and counseling were used to introduce the farmers to the benefits and risks of the implementation of a new business model that added Green elements to the traditional business model design. The paper concludes with recommendations for adaptations to the Framework and suggestions for future research.
This study investigates the determining factors that drive sustainable performance through the application of lean methods in the primary production segment of the horticultural supply chain for apples and pears. The determining factors, identified through a systematic review of the available literature, are thematically synthesized, conceptually framed and utilized for the development of a case study. The single case study approach is utilized to develop a detailed and nuanced understanding of the context, evaluating the practices of 4 cooperative primary producers operating within a forward integrated supply chain. The study posits that the combination of climatic and biophysical dynamism inherent in the primary producer environment, in combination with the inflexibility of seasonal batch production, imposes itself as a key barrier to the imposition of pull and flow in the chain, the fundamental tenets of a lean system. A case is outlined where cold infrastructure is employed to break the inflexibility of supply whilst a process of forward contracting establishes fruit orders up to 1-year in advance, beyond the forthcoming annual cultivation cycle, functionally transforming the system of cultivation from a “push” to a “pull” system of production. It is further highlighted that functional partitioning of the organizational-chain structure is necessary to isolate and mitigate the effects of contextual dynamism, whereby downstream chain structures purposed for agility and responsiveness serve as a protective buffer to lean focused grower operations. The findings reaffirm the positive relationship between the size of the grower operation, the capacitation of the workforce and the ability of the operation to attain superior performance outcomes. However, it is severally highlighted that horizontal cooperation between primary producers may help overcome the resource limitations of smaller growers. Data based decision controls are marked as being a centrally important sustainable performance determinant, both at the level of the grower, in terms of orchard management and harvest process control, as well as at the level of the cooperative serving the needs of crop programming and practice benchmarking processes. This exposition of determining factors driving lean sustainable performance in horticultural primary production represents a new contribution to the body of literature linking lean and sustainable organizational performance. The study should support further development of lean management research and operationalized lean methods within the fruit horticulture subsector as well as the broader agri-food context.
The purpose of this paper is to present a review and an analysis of the literature concerning a possible model for integrating three management systems: lean manufacturing, Six Sigma and sustainability. In particular, we analyzed current proposals and identified at the same time gaps in the existing literature from which we suggested future research directions for developing a specific integrated model, suggesting new opportunities and challenges that should be addressed by future studies. Both academicians and practitioners will find our review useful because it outlines the major lines of research in the field and their limitations.
The governance of labour in global production networks (GPNs) has become a critical area of concern amongst academics and policymakers alike. To date, GPN research has focused on the role of private company codes and multi-stakeholder ethical initiatives primarily driven by lead-firms. Other GPN studies highlight the critical role of civil society organisations (CSOs) in challenging lead-firm purchasing practices and shaping regulatory outcomes at local production sites. However, GPN research has not sufficiently incorporated the role of nation states in regulating work through legislative frameworks and enforcement regimes, often referred to in the literature as ‘state’ or ‘public’ governance. This is despite a ‘regulatory renaissance’ taking place across certain developing countries, seeking to strengthen their national regulatory labour institutions (Piore and Schrank, 2008:1).
The GPN framework provides an analytical lens through which to conceptualise cross-cutting strands of trans-scalar governance regimes, involving complex networks of state, private and civil society actors operating at multiple scales. Notions of territorial and societal embeddedness are used to elucidate how global ethical standards derived from particular country contexts become enmeshed in national regulatory frameworks and local societal relations, shaping governance outcomes for precarious workers incorporated into GPNs. The paper draws attention to the ‘trans-scalar embeddedness’ of labour governance regimes which interact across geographical scales and, in the case of South African fruit, reflect a ‘trans-scalar governance deficit’ for precarious workers. It is argued that the influence of national regulatory regimes should be more fully incorporated into analytical frameworks for understanding governance outcomes in GPNs.
Accounts of the spread of management ideas emphasizing the role of 'supply-side' actors underplay the active role recipients play in translating them into new and different forms. Comparing firms undergoing a similar process and looking at how a specific event unfolded, this paper aims to extend understanding of the concept of translation. It examines how ideas are rendered appropriate to a new setting through translation from the broad policy level into a set of specific practices. To do this, it looks at how a proposal to introduce lean management into the construction industry was applied within a set of firms and the projects they were undertaking. In the context of large 'distance' between the original arenas of the idea and its new one, the paper uncovers how the editing rules that are said to guide the process of translation are operationalized using a set of change interventions.
Purpose – The purpose of this paper is to investigate the applicability of lean and green practices to foundry industry in India for improving productivity and eliminating waste, incorporating the sustainability into business performance measures.
Design/methodology/approach – The study used survey questionnaire method to collect data against 16 lean and green practices from 71 middle- to senior-level professionals belonging to Indian foundry industry. The survey instrument of lean and green practices was developed based on a number of sources from the literature and formal discussions with academicians and foundry industry professionals. The responses were received on a five-point Likert scale ranging from least applicable to most applicable. Exploratory factor and reliability analyses are conducted to obtain and validate constructs and measure each constructs Cronbach’s α (i.e. a consistency coefficient). The lean and green practices are categorized into the four constructs, namely, workplace organization practices, management practices, inventory control practices, and industrial manufacturing and quality improvement practices. Further, descriptive statistics is employed to find out the relative significance of lean and green practices.
Findings – Factor and reliability analyses show that all four constructs are adequate and reliable to illustrate lean and green practices. Descriptive statistics indicates that lean and green practices are applicable for implementation to a certain extent in the foundry industry. Correlation analysis shows that lean practices are positively and moderately interrelated with green practices. Thus, the results present a strong evidence that lean and green practices are moderately applicable for implementation in the foundry industry.
Originality/value – The paper provides insights into the applicability of lean and green practices implementation in the context of a developing country and presents evidence that lean and green practices are moderately applicable in the foundry industry. In addition, this paper is one of the few efforts to promote sustainable development within the industry.
The purpose of this research paper is to evaluate the applicability and potential benefits of Lean Principles to a farm business. This research opted for a case study research strategy that is implemented through in-depth personal interviews with different actors along the supply chain. This is augmented by further data collection from experts in the field of Lean. Using the Five Principles of Lean, Value Stream Mapping and the Seven Wastes this study suggests that there are benefits from applying Lean Principles to a farm business in terms of reducing waste and improving the quality of food supply. The present study makes a contribution to the validity of Lean principles when applied to an agribusiness context.
Purpose ‐ The purpose of this paper is to examine the current state of lean adoption in Indian manufacturing plants and its impact on operational performance. Design/methodology/approach ‐ A survey questionnaire was developed and adapted based on work done in US industries. The survey questionnaire was sent to 400 firms in four geographic regions in India. In total, 79 usable responses were received for the study. Findings ‐ Since lean manufacturing is a multi-dimensional construct, the results demonstrate that approximately 80 percent of the respondents have implemented many dimensions of lean ‐ focus on customer needs, pull system, setup time reduction, total productive maintenance, supplier performance, statistical process control, and cross-departmental problem solving. The operational metrics have improved on all accounts: high productivity, reduced lead time, improved first-pass correct output, reduced inventory and space requirement. Interestingly, respondents have indicated that first-pass correct output, reduced manufacturing lead time, and increased productivity are the three main drivers of lean implementation. Research limitations/implications ‐ Since the sample size is not very large, the results need to be considered with caution. Originality/value ‐ Lean manufacturing is a very popular concept in the developed world and in some countries in the developing world as well. Yet, little is known about its current status in India, except for a few case studies. The study investigates the degree of lean production implementation in Indian manufacturing plants and its impact on operational metrics. The study also indicates the relationship between lean dimensions/practices and operational outcomes.
Purpose: Recent literature emphasizes the application of lean manufacturing practices to food processing industries in order to improve operational efficiency and productivity. Only a very limited number of studies have focused on the implementation of lean manufacturing practices within Small and Medium-sized Enterprises (SMEs) operating in the food sector. The majority of these studies used the case study method and concentrated on individual lean manufacturing techniques geared towards resolving efficiency issues. The objective of this empirical study is to analyze the status of the lean manufacturing practices and their benefits and barriers among European food processing SMEs.
Methodology: A structured questionnaire was developed to collect data. A total of 35 SMEs’ representatives, mostly CEOs and operations managers, participated in the survey. The study investigated the role of two control variables in lean implementation: size of the company and country of origin.
Finding: The findings show that lean manufacturing practice deployment in food processing SMEs is generally low and still evolving. However, some lean manufacturing practices are more prevalent than others: e.g. flow, pull and statistical process control are not widely used by the food processing SMEs whereas total productive maintenance, employee involvement and customer association are more widespread. The key barriers encountered by food SMEs in the implementation of lean manufacturing practices result from the special characteristics of the food sector such as highly perishable products, complicated processing, extremely variable raw materials, recipes, unpredictable demand, etc. Moreover, a lack of knowledge and resources makes it difficult for food processing SMEs to embark on the lean journey.
Originality: The gap in the literature regarding the application of lean manufacturing in food sector is identified and addressed in this study. The originality of this paper lies in analyzing the current status of the use of lean manufacturing practices among food SMEs in Europe and identifying potential barriers.
Lean as a business strategy is used to improve quality and service, eliminate waste, reduce time and costs, and enhance overall organizational effectiveness. Heightening challenges in competition in recent years have prompted many small and medium-sized enterprises (SMEs) to adopt lean to enhance firms’ competitiveness. This paper attempts to present an all-inclusive study and it examines various factors associated with the implementation of lean in SMEs in the U.S. The findings suggest that most of SMEs have a relatively accurate understanding of lean concept and philosophy. The primary reasons to implement lean are mainly internal, including reduce cost, improve profit margin, improve utilization of plant/facility, and maintain competitive position. A hierarchical cluster analysis was conducted to investigate lean status. It was discovered that both advanced adopters and beginners of lean are discovered. ANOVA test results show that there exist quite significant differences in terms of the degrees of lean implementation in SMEs. Varied lean tools and programs have been applied and they are positively related with firms’ performance. Lastly, the paper provides evidences that major lean barriers are encountered by SMEs regarding management or people related factors as well as key knowledge and know-how.
Success stories for applying supply chain methods to enhance agricultural industries are limited, despite their great potential. One key reason is that agricultural chains are subjected to the considerable managerial, social and biophysical complexity, which often leads to the inappropriate use of different methods. We capture supply chain complexity by formulating a matrix of biophysical by management factors. This is used to comprehend supply chain complexity and show how participants in agricultural chains can implement adaptation strategies that add value to their industry. Through various case studies we illustrate how adaptation strategies adopted by chain participants relate to different quadrants of the complexity matrix. An analysis of the literature based on this matrix also shows the suitability of different types of technical methods when used within adaptation strategies of each matrix quadrant. The complexity matrix aids the identification of the right strategies to use for the right problem through engagement with the right people.
The objective of this study is to develop a model for measuring adherence to lean practices for automotive part suppliers and to assess the relationship between the firm performance and the adoption of lean principles. This model has been developed by utilising the lean practices defined in the literature. The proposed model has been successfully applied to a large number of automotive part suppliers, and has been tested for its statistical validity. To test the proposed model, data were obtained from 207 automotive part suppliers by using the Computer-aided Telephone Interview method. Validity and reliability tests of the developed model of leanness are realised through exploratory and confirmatory factor analyses. Correlation analyses are used to examine the relationships between the lean applications and company performance and size. Analysis of Variance (ANOVA) is applied to reveal whether there are differences in the use of lean techniques across different company categories. The study shows that, in general, Turkish automotive part suppliers are performing their internal production in compliance with the lean manufacturing principles. Furthermore, it is found that there is a significant relationship between adaptation of lean principles by the supplier firms and their performance. The proposed model of leanness can be used by companies in the automotive industry to measure their leanness levels.
Purpose – The purpose of this paper is to investigate the impact of lean operations practice and design on the Chinese manufacturing performance, using lean assessment data from 65 plants in various industries. Design/methodology/approach – Exploratory factor and regression analyses are used to examine the associations among operations practice, production design, and operations performance. Three constructs are developed, two for operations practice (human resources and supply chains) and one for production design. Findings – Factor analysis shows that three factors are sufficient to represent the lean performance dimensions of flow, flexibility, and quality. Regression analysis shows that the lean performance factors are strongly related to operations practice and production system design. Using lean factors and operations practice/design, our results indicate significant gaps in lean manufacturing practices among different industries, with the petroleum and hi-tech industries performing relatively best. In addition, the garment industry performs very well in flexibility, indicating it does not compete just on price, but also on rapid response. Finally, all industries perform well in quality, underlining the emerging economy character of China. These results support other recent findings of the positive impact of lean operations on the performance of the Chinese manufacturing sector. Research limitations/implications – The paper's findings, which are based on the experience of selected manufacturing plants in China, should not be interpreted as indicative of the characteristics of the Chinese manufacturing plants in general. Originality/value – This paper advances the evidence on the role of lean manufacturing in two ways. First, to derive more robust statistical results, the paper relies on primary lean assessment data, as opposed to secondary opinion survey data common to most other studies. Second, to obtain more general findings, the paper makes use of a wider set of relevant variables, both for assessing manufacturing practice and performance, than is usual in the literature.
Purpose – To show how value chain analysis techniques have highlighted opportunities for strategic change in a UK agri-food supply chain and to present an initial model of an integrated supply chain based on the application of lean principles. Design/methodology/approach – The paper reports on action research carried in two red meat industry supply chains, each of which spanned the whole chain from farm to consumer. Both of these case studies involved teams of managers from the companies in the chains together with facilitation by the researcher. Findings – The paper builds on existing theoretical work to show that value chain analysis methods combined with lean principles can provide a powerful framework for the analysis and improvement of supply chain activity. Research limitations/implications – The research is based on case studies of only two supply chains both of which were related to pork products. It would be beneficial if further studies could be undertaken of other agri-food chains in meat and in other sectors, to further validate the findings and recommendations. Practical implications – A tentative model is proposed as the basis for the development of an integrated red meat supply chain Obstacles to the achievement of more efficient, integrated supply chains are highlighted and possible approaches to overcome these obstacles are suggested. Originality/value – The paper provides detailed suggestions as to the strategic implications and potential commercial benefits of adopting an integrated approach to the management of UK agri-food supply chains The paper should be of value both to researchers in this area and to senior managers who are responsible for the strategic development of agri-food supply chains.
The competitiveness of sixteen selected food commodity chains in South Africa was calculated using the Revealed Comparative Advantage method of Balassa. The majority of commodity chains are marginally competitive. Except for the maize, pineapple, and apple chains, the competitiveness index generally decreases when moving from primary to processed products. This implies that benification or “value adding” opportunities in South Africa we restricted. In order to compete in a global economy strategies should be followed that improve the competitiveness of the whole food supply chain. It is i.e. not good enough for farmers to be able to compete globally at farm gate level, whilst the locally processed commodities that is sold to the consumer is not competitive in the world market.
Cluster analysis is a statistical technique that sorts observations into similar sets or groups. The use of cluster analysis presents a complex challenge because it requires several methodological choices that determine the quality of a cluster solution. This paper chronicles the application of cluster analysis in strategic management research, where the technique has been used since the late 1970s to investigate issues of central importance. Analysis of 45 published strategy studies reveals that the implementation of cluster analysis has been often less than ideal, perhaps detracting from the ability of studies to generate knowledge. Given these findings, suggestions are offered for improving the application of cluster analysis in future inquiry.
The era of global flexibility has been described as one of generalised precariouness and vulnerability. Global integration is leading to changing patterns of employment, with declining permanent and increasingly insecure forms of work. This trend is typified in the South African export fruit sector. Reintegration into the global economy is leading to both the ‘modernisation’ and transformation of employment including the rapid rise of offfarm contract labour provided by third party agents. Within the South African fruit sector changes following global integration have been experienced through changes in the global value chain linking the sector to UK and European supermarkets, deregulation of domestic agriculture and export markets and the increase in state legislation affecting employment. These channels have all affected the linkages through which fruit producers access the global economy and are having significant implications for the employment strategies of producers. A dominant trend has been for producers to downsize their permanent on-farm labour and increase the employment of various categories of flexible off-farm labour – especially contract labour. This growing tendency towards the ‘externalisation’ of farm labour in South African fruit exports has raised new concerns regarding the vulnerability and poverty of farm workers as it means that a growing number of workers are being drawn into global production on the basis of low wages and insecure work outside the bounds of legislative protection. The paper explores the nature of contract employment and the implications of this type of employment for the lives of a group of workers drawn into its ambit. Using a qualitative methodology it examines the experiences of contract workers, not only of their work, but how their employment affects their ability to sustain family and community relations. Although the implications of global integration for contract workers are complex and mixed, our findings suggest an intensification of insecurity and vulnerability to poverty.
This article is a reflection on the path taken by production economics and farm management over the last century, and the progress made in understanding the economics of the farm. The accumulated knowledge has helped refine our assessment of the efficiency of farm management decisions and the evolving role of agriculture in modern society. Copyright 2010, Oxford University Press.
The paper presents a framework for developing country value chain analysis made up of three components. The first consists of identifying major constraints for value chain upgrading: market access restrictions, weak infrastructures, lacking resources and institutional voids. In the second component three elements of a value chain are defined: value addition, horizontal and vertical chain-network structure and value chain governance mechanisms. Finally, upgrading options are defined in the area of value addition, including the search for markets, the value chain- network structure and the governance form of the chain. Part of this component is the identification of the most suitable partnerships for upgrading the value chain. The three components of the framework are derived from major theoretical streams on inter-company relationships and from the literature on developing country value chains. The framework is applied in a case example of a developing country value chain
As operations management (OM) best practices have become mature, research on practices has begun to shift its interest from the justification of the value of those practices to the understanding of the contextual conditions under which they are effective-OM practice contingency research (OM PCR). This article sets out to examine and critique the current state of OM PCR. We review OM PCR studies through the lens of the major theoretical view on contingencies, contingency theory, along a number of relevant dimensions: contingency variables, performance variables, measurement, research design and employed form of fit. In this process, we put forward a number of tasks that need to be accomplished in order to move OM PCR forward and develop more solid conceptual foundations in which to anchor rigorous research in this area. Finally, we reflect on the theoretical arguments that underlie OM PCR (which are based on the contingency approach) and identify its limitations in fully explaining the currently observed patterns of use of OM practices and associated performance outcomes. As a result, we propose that in order to increase our understanding of these patterns, OM scholars need to study in more depth the process of selection of OM best practices by organizations. Accordingly, we put forward a framework to underpin such research integrating contingency theory and other theoretical perspectives.
Globalization results in both pressure and drivers for Chinese enterprises to improve their environmental performance. As a developing country, China has to balance economic and environmental performance. Green supply chain management (GSCM) is emerging to be an important approach for Chinese enterprises to improve performance, possibly on both these dimensions. Using empirical results from 186 respondents on GSCM practice in Chinese manufacturing enterprises, we examine the relationships between GSCM practice and environmental and economic performance. Using moderated hierarchical regression analysis, we evaluate the general relationships between specific GSCM practices and performance. We then investigate how two primary types of management operations philosophies, quality management and just-in-time (or lean) manufacturing principles, influence the relationship between GSCM practices and performance. Significant findings were determined for a number of relationships. Managerial implications are also identified.
Food Value Chain Analysis (FVCA) based on the lean paradigm is being applied to eight value chains in the UK red meat industry. This paper is based on the forth chain involving a value added pork for a major retailer. Systems theory is used to evaluate FVCA based on four sub-systems—goals and values, logistics, human resources and management structure. The results show a positive potential logistics benefits along the chain, but identified two key implementation issues; inter-company alignment of other sub-systems and chain organisational stability through time.
Management literature has suggested that contextual factors may present strong inertial forces within organizations that inhibit implementations that appear technically rational [R.R. Nelson, S.G. Winter, An Evolutionary Theory of Economic Change, Harvard University Press, Cambridge, MA, 1982]. This paper examines the effects of three contextual factors, plant size, plant age and unionization status, on the likelihood of implementing 22 manufacturing practices that are key facets of lean production systems. Further, we postulate four “bundles” of inter-related and internally consistent practices; these are just-in-time (JIT), total quality management (TQM), total preventive maintenance (TPM), and human resource management (HRM). We empirically validate our bundles and investigate their effects on operational performance. The study sample uses data from IndustryWeek’s Census of Manufacturers. The evidence provides strong support for the influence of plant size on lean implementation, whereas the influence of unionization and plant age is less pervasive than conventional wisdom suggests. The results also indicate that lean bundles contribute substantially to the operating performance of plants, and explain about 23% of the variation in operational performance after accounting for the effects of industry and contextual factors.