Lean manufacturing and operational excellence: drivers, barriers, and performance outcomes

Abstract

Background: Lean manufacturing which is a subset of the Toyota Production System is one of the foundation blocks of operational excellence, which is constructed based on procedural waste removal, ongoing quality improvement, and customer perceived value creation. With its extensive implementation, successful implementation and sustainability are still a challenge among organizations.

Purpose: The purpose of this paper is to review the enabler, major obstacles, and quantifiable performance drivers that relate to lean transformation initiatives in manufacturing settings.

Methods: The mixed system was utilized; it has included a systematic literature review of 22 peer-reviewed articles (2015-2024) with a sample size of 156 manufacturing companies operating within the car sector, electronic area, and the FMCG. Associations between lean drivers, barriers, and results were identified by descriptive statistics, regression modeling, and correlation analysis.

Findings: The top management commitment, formal lean training systems, and process visibility supported by technology were ranked the largest enablers of effective lean implementation (p < 0.01). The main challenges observed consisted of an organizational attitude towards change, the lack of lean expertise, and temporary financial orientation. The average increase in saved time during the production cycle was 39.1, defect rate declined by 69.1, inventory turnover enhanced by 88.1, and overall equipment effectiveness increased by 34.9 on average by companies that applied lean practices successfully.

Bottom line: The results conceptualize the imperative importance of utilizing lean thinking as reflective of leadership in the attainment of the operational excellence over the long run. Organizations that adopt lean tools in an environment of continuous improvement have always been ahead of others. These findings can provide invaluable practitioners and researchers involved in challenging lean transformation processes in complex manufacturing environments with practical advice.