Difficulties observed during lean tools training: insights for leaders
DOI:
https://doi.org/10.5902/1983465963914Keywords:
Lean manufacturing, Lean philosophy, Training, Operational level, TOPSIS.Abstract
Purpose: The lean manufacturing can be an important ally of companies to enhance their competitiveness, since it can support companies to eliminate wastes and continuously improve their processes. In this context, the main purpose of this study was to analyze difficulties observed by operational level employees of auto parts companies during lean tools training.
Design/methodology/approach: A panel of specialists indicated 18 tools required for lean journey training. These tools were used to structure a questionnaire to perform a survey. The survey was conducted with 77 lean training experienced professionals from two auto parts companies. Data collected was analyzed through descriptive statistics and Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS), to rank the tools according to the difficulty levels observed by the respondents.
Findings: In general, operational level employees presented difficulties to understand the concepts of all analyzed tools. Comparatively, Lean Leadership and Constraints Management were those most difficult for them.
Originality/value: The results present here can be used by leaders for providing lean training and for academics in futures studies.
Downloads
References
Arghode, Vishal, and Jia Wang. 2016. “Exploring Trainers’ Engaging Instructional Practices: A Collective Case Study.” European Journal of Training and Development 40(2): 111–27. https://www.emerald.com/insight/content/doi/10.1108/EJTD-04-2015-0033/full/html.
Awais Bhatti, Muhammad, and Sharan Kaur. 2010. “The Role of Individual and Training Design Factors on Training Transfer.” Journal of European Industrial Training 34(7): 656–72. https://www.emerald.com/insight/content/doi/10.1108/03090591011070770/full/html.
Costa, Leandro Santos da, and Antonio Marcos Duarte Junior. 2013. “Uma Metodologia Para a Pré-Seleção de Ações Utilizando o Método Multicritério TOPSIS.” In XLV Simpósio Brasileiro de Pesquisa Operacional, Natal, 518–29.
Dandage, Rahul, Shankar S. Mantha, and Santosh B. Rane. 2018. “Ranking the Risk Categories in International Projects Using the TOPSIS Method.” International Journal of Managing Projects in Business 11(2): 317–31. https://www.emerald.com/insight/content/doi/10.1108/IJMPB-06-2017-0070/full/html.
Dombrowski, U., and T. Mielke. 2014. “Lean Leadership – 15 Rules for a Sustainable Lean Implementation.” Procedia CIRP 17: 565–70. https://linkinghub.elsevier.com/retrieve/pii/S2212827114004259.
Enke, Judith, Rupert Glass, and Joachim Metternich. 2017. “Introducing a Maturity Model for Learning Factories.” Procedia Manufacturing 9: 1–8. http://dx.doi.org/10.1016/j.promfg.2017.04.010.
Etter, Gregg W., and Richard Griffin. 2011. “In-Service Training of Older Law Enforcement Officers: An Andragogical Argument.” Policing 34(2): 233–45.
Gordon, Geoffrey L. et al. 2012. “The Training of Sales Managers: Current Practices.” Journal of Business & Industrial Marketing 27(8): 659–72. https://www.emerald.com/insight/content/doi/10.1108/08858621211273600/full/html.
Hair, Joseph F. et al. 2011. Essentials of Business Research Methods. 2nd ed. Armonk: Routledge.
Harris, Greg et al. 2014. “Transitioning from Teaching Lean Tools To Teaching Lean Transformation.” Journal of Enterprise Transformation 4(3): 191–204. http://www.tandfonline.com/doi/abs/10.1080/19488289.2014.930545.
Hines, Peter, Matthias Holweg, and Nick Rich. 2004. “Learning to Evolve.” International Journal of Operations & Production Management 24(10): 994–1011. https://www.emerald.com/insight/content/doi/10.1108/01443570410558049/full/html.
House, Stephanie C., Kimberly C. Spencer, and Christine Pfund. 2018. “Understanding How Diversity Training Impacts Faculty Mentors’ Awareness and Behavior.” International Journal of Mentoring and Coaching in Education 7(1): 72–86. https://www.emerald.com/insight/content/doi/10.1108/IJMCE-03-2017-0020/full/html.
Hwang, Ching-Lai, and Kwangsun Yoon. 1981. 186 Multiple Attribute Decision Making. Berlin, Heidelberg: Springer Berlin Heidelberg. http://link.springer.com/10.1007/978-3-642-48318-9.
Isack, Hilma Dhiginina et al. 2018. “Exploring the Adoption of Lean Principles in Medical Laboratory Industry.” International Journal of Lean Six Sigma 9(1): 133–55. https://www.emerald.com/insight/content/doi/10.1108/IJLSS-02-2017-0017/full/html.
Jadhav, Jagdish R., Shankar S. Mantha, and Santosh B. Rane. 2014. “Exploring Barriers in Lean Implementation.” International Journal of Lean Six Sigma 5(2): 122–48. http://www.emeraldinsight.com/doi/abs/10.1108/IJLSS-12-2012-0014.
Jeffrey, Lynn M., Sophie Hide, and Stephen Legg. 2010. “Learning Characteristics of Small Business Managers: Principles for Training.” Journal of Workplace Learning 22(3): 146–65. https://www.emerald.com/insight/content/doi/10.1108/13665621011028602/full/html.
Karim, Azharul, and Kazi Arif‐Uz‐Zaman. 2013. “A Methodology for Effective Implementation of Lean Strategies and Its Performance Evaluation in Manufacturing Organizations.” Business Process Management Journal 19(1): 169–96. http://www.scopus.com/inward/record.url?eid=2-s2.0-84873422488&partnerID=tZOtx3y1.
Lauver, Kristy J., Abraham Y. Nahm, Brent S. Opall, and James P. Keyes. 2018. “Becoming Lean: The Employee Perspective.” Journal of Business Strategy 39(6): 43–49. https://www.emerald.com/insight/content/doi/10.1108/JBS-04-2017-0041/full/html.
Liker, J. K. 2005. O Modelo Toyota – 14 Princípios de Gestão Do Maior Fabricante Do Mundo [The Toyota Way: 14 Management Principles from the World’s Greatest Manufacturer]. Porto Alegre: Bookman.
Maskell, Brian H., and Frances A. Kennedy. 2007. “Why Do We Need Lean Accounting and How Does It Work?” Journal of Corporate Accounting & Finance 18(3): 59–73. http://doi.wiley.com/10.1002/jcaf.20293.
Nogueira, Daniela Maria da Costa, Paulo S.A. Sousa, and Maria R.A. Moreira. 2018. “The Relationship between Leadership Style and the Success of Lean Management Implementation.” Leadership & Organization Development Journal 39(6): 807–24. https://www.emerald.com/insight/content/doi/10.1108/LODJ-05-2018-0192/full/html.
Ohno, Taichi. 1997. O Sistema Toyota de Produção: Além Da Produção Em Larga Escala [Toyota Production System – Beyond Large-Scale Production]. Porto Alegre: Bookman.
Rampasso, Izabela S. et al. 2019. “Maturity Analysis of Manufacturing Cells.” Production Planning & Control 30(15): 1250–64. https://doi.org/10.1080/09537287.2019.1612108.
Rodríguez, Denise, Dirk Buyens, Hendrik Van Landeghem, and Virginia Lasio. 2016. “Impact of Lean Production on Perceived Job Autonomy and Job Satisfaction: An Experimental Study.” Human Factors and Ergonomics in Manufacturing & Service Industries 26(2): 159–76. http://scholar.google.com/scholar?hl=en&btnG=Search&q=intitle:Human+Motion+Simulation+for+Vehicle+and+Workplace+Design#1.
Shahin, Arash, Angappa Gunasekaran, Azam Khalili, and Hadi Shirouyehzad. 2016. “A New Approach for Estimating Leagile Decoupling Point Using Data Envelopment Analysis.” Assembly Automation 36(3): 233–45.
Sharma, Vikram, Amit Rai Dixit, and Mohd Asim Qadri. 2016. “Modeling Lean Implementation for Manufacturing Sector.” Journal of Modelling in Management 11(2): 405–26. https://www.emerald.com/insight/content/doi/10.1108/JM2-05-2014-0040/full/html.
Shingo, S. 1996. O Sistema Toyota de Produção – Do Ponto de Vista Da Engenharia de Produção [The Toyota Production System - From a Production Engineering Viewpoint]. 2nd ed. Porto Alegre: Artes Médicas.
Singh, Rajesh Kumar, Ayush Gupta, Ashok Kumar, and Tasmeem Ahmad Khan. 2016. “Ranking of Barriers for Effective Maintenance by Using TOPSIS Approach.” Journal of Quality in Maintenance Engineering 22(1): 18–34. http://www.emeraldinsight.com/doi/10.1108/JQME-02-2015-0009.
Smeds, Riitta. 2003. “Simulation for Accelerated Learning and Development in Industrial Management.” Production Planning & Control 14(2): 107–10. https://www.tandfonline.com/doi/full/10.1080/0953728031000107707.
Stimec, Arnaud. 2020. “Lean Management and Occupational Health: Team Learning as a Key Factor.” Journal of Workplace Learning 32(5): 363–75.
Tortorella, Guilherme, and Flávio Fogliatto. 2017. “Implementation of Lean Manufacturing and Situational Leadership Styles: An Empirical Study.” Leadership and Organization Development Journal 38(7): 946–68.
Veile, Johannes W., Daniel Kiel, Julian Marius Müller, and Kai-Ingo Voigt. 2019. “Lessons Learned from Industry 4.0 Implementation in the German Manufacturing Industry.” Journal of Manufacturing Technology Management ahead-of-p(ahead-of-print). https://www.emerald.com/insight/content/doi/10.1108/JMTM-08-2018-0270/full/html.
Womack, James P., and Daniel T. Jones. 2003. Lean Thinking: Banish Waste and Create Wealth in Your Corporation. New York: Free Press.
Yang, Taho, Yuan Feng Wen, Zong Rui Hsieh, and Jianxia Zhang. 2020. “A Lean Production System Design for Semiconductor Crystal-Ingot Pulling Manufacturing Using Hybrid Taguchi Method and Simulation Optimization.” Assembly Automation 40(3): 433–45.
Yasukawa, Keiko, Tony Brown, and Stephen Black. 2014. “Disturbing Practices: Training Workers to Be Lean” eds. Prof. Tara Fenwick and Prof. John Field. Journal of Workplace Learning 26(6/7): 392–405. https://www.emerald.com/insight/content/doi/10.1108/JWL-09-2013-0068/full/html.
De Zan, Giovanni, Alberto Felice De Toni, Andrea Fornasier, and Cinzia Battistella. 2015. “A Methodology for the Assessment of Experiential Learning Lean.” European Journal of Training and Development 39(4): 332–54. https://www.emerald.com/insight/content/doi/10.1108/EJTD-05-2014-0040/full/html.
Published
How to Cite
Issue
Section
License
Copyright (c) 2021 Revista de Administração da UFSM
This work is licensed under a Creative Commons Attribution 4.0 International License.
Authors of articles published by ReA/UFSM retain the copyright of their works, licensing them under the Creative Commons (CC-BY 4.0), which allows articles to be reused and distributed without restriction, provided that the original work is properly cited.