Perception of shop floor employees regarding senior management support in lean projects and its relationship with initiatives success
Keywords:Lean manufacturing, Lean manufacturing performance, Senior management, Leadership, PLS-SEM.
Purpose – Over the years, the lean production philosophy has shown satisfactory results for companies from different sectors in different countries. Aiming to contribute to the knowledge base on the mentioned philosophy, this study aims to verify the perception of shop floor employees regarding senior management support in lean projects and its relationship with initiatives success.
Design/methodology/approach – Through a literature review, 18 aspects of a lean journey were identified and divided into four constructs by a panel of specialists. This information was used to compose a questionnaire, and a survey was conducted with 198 shop floor employees of two auto parts companies. Data analysis was done via Structural Equation Modeling.
Findings – As a general result, it was possible to prove that when employees perceive more significant support from senior management in lean projects, the greater is the perception of initiatives success. Therefore, it is interesting that the involvement of senior management occurs at all stages of the project.
Originality/value – The results described here have practical implications, especially for managers interested in implementing lean projects; they must be aware of the importance of senior management support for the success of previous projects.
Alagaraja, M., & Egan, T. (2013). The Strategic Value of HRD in Lean Strategy Implementation. Human Resource Development Quarterly, 24(1), 1–27. https://doi.org/10.1002/hrdq.21155
Angelis, J., Conti, R., Cooper, C., & Gill, C. (2011). Building a high‐commitment lean culture. Journal of Manufacturing Technology Management, 22(5), 569–586. https://doi.org/10.1108/17410381111134446
Azambuja, R. (2011). Influence of the knowledge of workers in a lean manufacturing system on the production indicators of an automobile company (Influência do conhecimento dos trabalhadores em sistema de manufatura enxuta sobre os indicadores de produção de uma empresa automo. University of Campinas.
Ballé, M., & Régnier, A. (2007). Lean as a learning system in a hospital ward. Leadership in Health Services, 20(1), 33–41. https://doi.org/10.1108/17511870710721471
Bevilacqua, M., Ciarapica, F. E., & De Sanctis, I. (2017). Relationships between Italian companies’ operational characteristics and business growth in high and low lean performers. Journal of Manufacturing Technology Management, 28(2), 250–274. https://doi.org/10.1108/JMTM-02-2016-0024
Bhasin, S. (2012a). Prominent obstacles to lean. International Journal of Productivity and Performance Management, 61(4), 403–425. https://doi.org/10.1108/17410401211212661
Bhasin, S. (2012b). An appropriate change strategy for lean success. Management Decision, 50(3), 439–458. https://doi.org/10.1108/00251741211216223
Binti Aminuddin, N. A., Garza-Reyes, J. A., Kumar, V., Antony, J., & Rocha-Lona, L. (2016). An analysis of managerial factors affecting the implementation and use of overall equipment effectiveness. International Journal of Production Research, 54(15), 4430–4447. https://doi.org/10.1080/00207543.2015.1055849
Birkie, S. E., Trucco, P., & Kaulio, M. (2017). Sustaining performance under operational turbulence. International Journal of Lean Six Sigma, 8(4), 457–481. https://doi.org/10.1108/IJLSS-12-2016-0077
Botti, L., Mora, C., & Regattieri, A. (2017). Integrating ergonomics and lean manufacturing principles in a hybrid assembly line. Computers & Industrial Engineering, 111, 481–491. https://doi.org/10.1016/j.cie.2017.05.011
Braglia, M., Gabbrielli, R., & Marrazzini, L. (2019). Overall Task Effectiveness: a new Lean performance indicator in engineer-to-order environment. International Journal of Productivity and Performance Management, 68(2), 407–422. https://doi.org/10.1108/IJPPM-05-2018-0192
Cohen, J. (1988). Statistical Power Analysis for the Behavioral Sciences (2nd ed.). Psychology Press.
de Oliveira, R. I., Sousa, S. O., & de Campos, F. C. (2019). Lean manufacturing implementation: bibliometric analysis 2007–2018. The International Journal of Advanced Manufacturing Technology, 101(1–4), 979–988. https://doi.org/10.1007/s00170-018-2965-y
Dombrowski, U., & Mielke, T. (2014). Lean Leadership – 15 Rules for a Sustainable Lean Implementation. Procedia CIRP, 17, 565–570. https://doi.org/10.1016/j.procir.2014.01.146
Emiliani, M. L. (1998). Lean behaviors. Management Decision, 36(9), 615–631. https://doi.org/10.1108/00251749810239504
Gamme, I., & H. Aschehoug, S. (2014). Assessing lean’s impact on operational integration. International Journal of Quality and Service Sciences, 6(2/3), 112–123. https://doi.org/10.1108/IJQSS-02-2014-0013
Guzzo, C., Maccari, E. A., & Piscopo, M. R. (2012). Sistematização de um modelo de lições aprendidas em projetos como contribuição à aprendizagem organizacional. Revista Gestão e Planejamento, 12(3), 578–593.
Hair, J. F., Hult, G. T. M., Ringle, C. M., & Sarstedt, M. (2017). A primer on partial least squares structural equation modeling (PLS-SEM) (2nd ed.). SAGE Publications, Inc.
Hair, J. F., Hult, G. T. M., Ringle, C., & Sarstedt, M. (2014). A primer on partial least squares structural equation modeling (PLS-SEM). Sage Publications.
Hair, J. F., Wolfinbarger, M., Money, A. H., Samouel, P., & Page, M. J. (2011). Essentials of Business Research Methods (2nd ed.). Routledge.
Henseler, J., Ringle, C. M., & Sinkovics, R. R. (2009). The use of partial least squares path modeling in international marketing. In Advances in International Marketing 20 (pp. 277–319). https://doi.org/10.1108/S1474-7979(2009)0000020014
Imam, H., & Chambel, M. J. (2020). Productivity or illusion? Assessing employees’ behavior in an employability paradox. Employee Relations: The International Journal, 42(6), 1271–1289. https://doi.org/10.1108/ER-11-2019-0446
Jadhav, J. R., Mantha, S. S., & Rane, S. B. (2014). Exploring barriers in lean implementation. International Journal of Lean Six Sigma, 5(2), 122–148. https://doi.org/10.1108/IJLSS-12-2012-0014
Jagoda, K., Lonseth, R., & Lonseth, A. (2013). A bottom‐up approach for productivity measurement and improvement. International Journal of Productivity and Performance Management, 62(4), 387–406. https://doi.org/10.1108/17410401311329625
Jarvis, C. B., MacKenzie, S. B., & Podsakoff, P. M. (2003). A Critical Review of Construct Indicators and Measurement Model Misspecification in Marketing and Consumer Research. Journal of Consumer Research, 30(2), 199–218. https://doi.org/10.1086/376806
Júnior, S. B., Silva, D. Da, Moretti, S. L. do A., & Lopes, E. L. (2012). UMA ANÁLISE DA CONSCIÊNCIA ECOLÓGICA PARA O CONSUMO “VERDE” NO VAREJO SUPERMERCADISTA. Revista de Gestão Social e Ambiental, 6(2). https://doi.org/10.5773/rgsa.v6i2.533
Karim, A., & Arif‐Uz‐Zaman, K. (2013). A methodology for effective implementation of lean strategies and its performance evaluation in manufacturing organizations. Business Process Management Journal, 19(1), 169–196. https://doi.org/10.1108/14637151311294912
Kim, B.-C. (2015). Dynamic Control Thresholds for Consistent Earned Value Analysis and Reliable Early Warning. Journal of Management in Engineering, 31(5), 04014077. https://doi.org/10.1061/(ASCE)ME.1943-5479.0000309
Lantz, A., Hansen, N., & Antoni, C. (2015). Participative work design in lean production. Journal of Workplace Learning, 27(1), 19–33. https://doi.org/10.1108/JWL-03-2014-0026
Laser, J. (2020). The best equilibrium in organizational flexibility-stability continuums. International Journal of Organizational Analysis. https://doi.org/10.1108/IJOA-09-2019-1875
Laureani, A., & Antony, J. (2012). Critical success factors for the effective implementation of Lean Sigma. International Journal of Lean Six Sigma, 3(4), 274–283. https://doi.org/10.1108/20401461211284743
Lewis, M. A. (2000). Lean production and sustainable competitive advantage. International Journal of Operations & Production Management, 20(8), 959–978. https://doi.org/10.1108/01443570010332971
Mainga, W. (2017). Examining project learning, project management competencies, and project efficiency in project-based firms (PBFs). International Journal of Managing Projects in Business, 10(3), 454–504. https://doi.org/10.1108/IJMPB-04-2016-0035
Martins, V. W. B., Rampasso, I. S., Anholon, R., Quelhas, O. L. G., & Leal Filho, W. (2019). Knowledge management in the context of sustainability: Literature review and opportunities for future research. Journal of Cleaner Production, 229, 489–500. https://doi.org/10.1016/j.jclepro.2019.04.354
Milton, N. (2010). The Lessons Learned Handbook: Practical Approaches to Learning from Experience. Chandos Publishing.
Möldner, A. K., Garza-Reyes, J. A., & Kumar, V. (2020). Exploring lean manufacturing practices’ influence on process innovation performance. Journal of Business Research, 106(September 2018), 233–249. https://doi.org/10.1016/j.jbusres.2018.09.002
Nascimento, D. L. de M., Goncalvez Quelhas, O. L., Gusmão Caiado, R. G., Tortorella, G. L., Garza-Reyes, J. A., & Rocha-Lona, L. (2019). A lean six sigma framework for continuous and incremental improvement in the oil and gas sector. International Journal of Lean Six Sigma. https://doi.org/10.1108/IJLSS-02-2019-0011
Nogueira, D. M. da C., Sousa, P. S. A., & Moreira, M. R. A. (2018). The relationship between leadership style and the success of Lean management implementation. Leadership & Organization Development Journal, 39(6), 807–824. https://doi.org/10.1108/LODJ-05-2018-0192
Nunes, R. D. S., Jacobsen, A. D. L., & Cardoso, R. D. S. (2019). Manufatura enxuta em um fabricante de produtos hospitalares: implantação e avaliação na percepção dos gestores. Revista de Administração Da UFSM, 12(1), 88–106. https://doi.org/10.5902/1983465917638
Rahbek Gjerdrum Pedersen, E., & Huniche, M. (2011). Determinants of lean success and failure in the Danish public sector. International Journal of Public Sector Management, 24(5), 403–420. https://doi.org/10.1108/09513551111147141
Rampasso, I. S., Anholon, R., Gonçalves Quelhas, O. L., & Filho, W. L. (2017). Primary problems associated with the health and welfare of employees observed when implementing lean manufacturing projects. Work, 58(3), 263–275. https://doi.org/10.3233/WOR-172632
Rampasso, Izabela S., Anholon, R., da Silva, D., Ordóñez, R. E. C., & Quelhas, O. L. G. (2019). Maturity analysis of manufacturing cells. Production Planning & Control, 30(15), 1250–1264. https://doi.org/10.1080/09537287.2019.1612108
Randhawa, J. S., & Ahuja, I. S. (2017). 5S – a quality improvement tool for sustainable performance: literature review and directions. International Journal of Quality & Reliability Management, 34(3), 334–361. https://doi.org/10.1108/IJQRM-03-2015-0045
Rich, N., & Bateman, N. (2003). Companies’ perceptions of inhibitors and enablers for process improvement activities. International Journal of Operations & Production Management, 23(2), 185–199. https://doi.org/10.1108/01443570310458447
Ringle, C. M., Da Silva, D., & Bido, D. D. S. (2014). Structural Equation Modeling with the Smartpls. Revista Brasileira de Marketing, 13(2), 56–73. https://doi.org/10.5585/remark.v13i2.2717
Scherrer-Rathje, M., Boyle, T. A., & Deflorin, P. (2009). Lean, take two! Reflections from the second attempt at lean implementation. Business Horizons, 52(1), 79–88. https://doi.org/10.1016/j.bushor.2008.08.004
Shahin, M., Chen, F. F., Bouzary, H., & Krishnaiyer, K. (2020). Integration of Lean practices and Industry 4.0 technologies: smart manufacturing for next-generation enterprises. The International Journal of Advanced Manufacturing Technology. https://doi.org/10.1007/s00170-020-05124-0
Shi, Y., Wang, X., & Zhu, X. (2019). Lean manufacturing and productivity changes: the moderating role of R&D. International Journal of Productivity and Performance Management, 69(1), 169–191. https://doi.org/10.1108/IJPPM-03-2018-0117
Signoretti, A. (2020). Overcoming the barriers to the implementation of more efficient productive strategies in small enterprises. Employee Relations: The International Journal, 42(1), 149–165. https://doi.org/10.1108/ER-11-2018-0298
Silva, M. C., Anholon, R., Rampasso, I. S., Quelhas, O. L. G., Filho, W. L., & Silva, D. Da. (2018). Analysis of the Brazilian entrepreneurial ecosystem in the perception of business incubator professionals. International Journal of Business Innovation and Research, 16(4), 507. https://doi.org/10.1504/IJBIR.2018.093524
Sisson, J., & Elshennawy, A. (2015). Achieving success with Lean. International Journal of Lean Six Sigma, 6(3), 263–280. https://doi.org/10.1108/IJLSS-07-2014-0024
Slack, N., Brandon-Jones, A., & Johnston, R. (2013). Operations Management. Pearson.
Solaimani, S., Haghighi Talab, A., & van der Rhee, B. (2019). An integrative view on Lean innovation management. Journal of Business Research, 105(July), 109–120. https://doi.org/10.1016/j.jbusres.2019.07.042
T., R., & K.P., S. (2021). Identification and modeling of process barriers. International Journal of Lean Six Sigma, 12(1), 61–77. https://doi.org/10.1108/IJLSS-09-2016-0044
Tortorella, G., & Fogliatto, F. (2017). Implementation of lean manufacturing and situational leadership styles: An empirical study. Leadership and Organization Development Journal, 38(7), 946–968. https://doi.org/10.1108/LODJ-07-2016-0165
Vasconcelos, D. C., Viana, F. E., & Neto, J. D. P. B. (2019). Lean and green: the contribution of lean production and environmental management to the waste reduction. Revista de Administração Da UFSM, 12(2), 365–383. https://doi.org/10.5902/1983465921750
Wetzels, M., Odekerken-Schoroder, G., & Oppen, C. V. (2009). Using PLS path modeling for assessing hierarchical construct models: guidelines and empirical illustration. MIS Quarterly, 33(1), 177–195. http://www.jstor.org/stable/20650284
Wong, Y. C., Wong, K. Y., & Ali, A. (2009). A study on lean manufacturing implementation in the Malaysian electrical and electronics industry. European Journal of Scientific Research, 38(4), 521–535.
Worley, J. M., & Doolen, T. L. (2015). Organizational structure, employee problem solving, and lean implementation. International Journal of Lean Six Sigma, 6(1), 39–58. https://doi.org/10.1108/IJLSS-12-2013-0058
Wu, D., & Passerini, K. (2013). Uncovering knowledge‐based time management practices. International Journal of Managing Projects in Business, 6(2), 332–348. https://doi.org/10.1108/17538371311319052
Yang, T., Wen, Y. F., Hsieh, Z. R., & Zhang, J. (2020). A lean production system design for semiconductor crystal-ingot pulling manufacturing using hybrid Taguchi method and simulation optimization. Assembly Automation, 40(3), 433–445. https://doi.org/10.1108/AA-11-2018-0193
Zhang, L., Narkhede, B. E., & Chaple, A. P. (2017). Evaluating lean manufacturing barriers: an interpretive process. Journal of Manufacturing Technology Management, 28(8), 1086–1114. https://doi.org/10.1108/JMTM-04-2017-0071
How to Cite
Copyright (c) 2022 Revista de Administração da UFSM
This work is licensed under a Creative Commons Attribution 4.0 International License.
This journal remains the copyright holders of articles published. In order to be published, authors must sign the Copyrights Letter, which is sent to the authors by e-mail, thus granting rights, including on translation, to ReA/UFSM. The journal grants third parties the right to use, reproduce, and share the article according to the Creative Commons license agreement (CC-BY 4.0), as stated in the article’s PDF documents.