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Performance evaluation of lean manufacturing implementation in Brazil

Author

Listed:
  • Wagner Cezar Lucato
  • Felipe Araujo Calarge
  • Mauro Loureiro Junior
  • Robisom Damasceno Calado

Abstract

Purpose - – Manufacturing companies worldwide have been replacing traditional mass-production practices by lean initiatives. This translation process is progressive and may vary depending on several factors. Hence, it could be expected that the degree of adoption of the lean practices could vary significantly among industries, regions and even countries. The purpose of this paper is to explore the implementation performance of lean principles in Brazil, the paper developed a survey in the Sao Paulo Metropolitan Area, which considered 51 industries of different sizes, from several industrial segments, nationals and multinationals. Design/methodology/approach - – The proposed survey was developed using as a normative framework the SAE J4000 standard – identification and measurement of the best practice in implementation of lean operation and the SAE J4001 – implementation of lean operation user manual. To measure the implementation degree of the lean practices in the researched industries, the paper proposed the utilization of two concepts: the degree of leanness (DOL) of an element of J4000 and DOL of a company. Also three hypotheses were tested, trying to establish the relationship among the DOL and firm ownership, their size and respective industrial sector. Findings - – The results obtained in the survey demonstrated that the performance of lean initiative implementation is not uniform among the companies located in the researched area. Outcomes also showed that the degree of implementation of the lean practices by multinational companies was higher than that for the national firms. However, it was not possible to establish a relationship between the DOL and the size of the firms. Neither a clear and definite association between DOL and industrial sector was possible to be identified. Practical implications - – For the practitioners and managers dealing with the lean implementation, this paper gives a relevant contribution because it shows how they can effectively use an existing tool to measure the implementation of the lean practices in their respective firms. Furthermore, the DOL calculation for each individual element of the J4000 standard could also be used by practitioners and managers to identify specific problems and opportunity areas where practical actions could be identified to improve the lean implementation. Originality/value - – This paper contributes to the lean manufacturing theory because it proposes a theoretical way to measure the degree of implementation of the lean initiatives in the manufacturing companies. Also the survey results generate additional research material that could be used by other researchers to further explore the subject in the area.

Suggested Citation

  • Wagner Cezar Lucato & Felipe Araujo Calarge & Mauro Loureiro Junior & Robisom Damasceno Calado, 2014. "Performance evaluation of lean manufacturing implementation in Brazil," International Journal of Productivity and Performance Management, Emerald Group Publishing Limited, vol. 63(5), pages 529-549, June.
  • Handle: RePEc:eme:ijppmp:v:63:y:2014:i:5:p:529-549
    DOI: 10.1108/IJPPM-04-2013-0085
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    Citations

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    Cited by:

    1. Luana Bonome Message Costa & Moacir Godinho Filho & Antonio Freitas Rentes & Thiago Moreno Bertani & Ronaldo Mardegan, 2017. "Lean healthcare in developing countries: evidence from Brazilian hospitals," International Journal of Health Planning and Management, Wiley Blackwell, vol. 32(1), pages 99-120, January.
    2. Ravindra Ojha, 2021. "Enablers of Lean for Manufacturing Excellence: An Interpretive Structural Modelling and Analysis," Vision, , vol. 26(1), pages 90-104, March.
    3. Simone Zamin & Leandro José Nichetti & José Antonio Cescon & Vinícius Abílio Martins & Nilton César Lima, 2021. "Lean Practices in the Process of New Product Development: Case of Study in a Food Industry Cooperative in Brazil," Journal of Agricultural Studies, Macrothink Institute, vol. 9(4), pages 41-61, December.
    4. Lara Göhner & Luiz Carlos Brasil de Brito Mello & Renata Albergaria de Mello Bandeira, 2017. "Implementation Of Lean Manufacturing In Multinational Companies With Production Subsidiaries In Brazil: A Roadmap," Portuguese Journal of Management Studies, ISEG, Universidade de Lisboa, vol. 22(2), pages 99-123.
    5. Gusman Nawanir & Yudi Fernando & Lim Kong Teong, 2018. "A Second-order Model of Lean Manufacturing Implementation to Leverage Production Line Productivity with the Importance-Performance Map Analysis," Global Business Review, International Management Institute, vol. 19(3_suppl), pages 114-129, June.

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