Towards greater understanding of success and survival of lean systems

Abstract

The purposes of this research are to remove some of the confusion surrounding the characterisation of lean systems; to delve deeper into the human issues associated with lean; and to explore the complexity of an established lean system to identify issues which affect its success and ongoing continuance. Using the mixed methods of literature analysis, semi-structured interviews and document analysis, we examine the lean implementation in one site of an international car manufacturer. We claim several contributions for the work. First, we produce a literature-based taxonomy defining the core dimensions of lean – this gives managers a clear roadmap for lean implementation. A second contribution is a detailed delineation of the human issues of lean, from which managers can follow our set of themes to guide their managerial efforts. Finally, we provide insights into the inner workings of a lean system showing several examples of the delicate balances and tensions which exist. Perhaps none is as significant as the issue of its long term survival, which our findings suggest may be at risk. This serves as a warning signal to managers to be on constant lookout for signs of faltering or failure.

Keywords:

• lean operations
• human issues in lean
• lean taxonomy
• automotive manufacturing
• case study research