A lean manufacturing implementation framework for the Malaysian electrical and electronics industry

Abstract

Lean manufacturing has gained a lot of attention across the world. However, not much information can be drawn in terms of how it is implemented in Malaysia. The purpose of this study was to develop a framework that would assist the electrical and electronics industry in Malaysia to implement lean manufacturing in a more structured way. In order to achieve this, the implementation of lean manufacturing in this industry was investigated using the survey and case study methods. At the outset, 14 key areas which characterized lean manufacturing were proposed based on a comprehensive review of the literature. They were scheduling, inventory, material handling, equipment, work processes, quality, employees, layout, suppliers, customers, safety and ergonomics, product design, management and culture, and tools and techniques. A survey was then carried out to assess the implementation level of these key areas together with other issues such as the benefits and obstacles of implementing lean manufacturing. It was found that all the key areas were averagely implemented and the relevance of the 14 key areas has been substantiated. Following this, case studies were conducted in four electrical and electronics companies in Malaysia to investigate how they have adopted and embraced lean manufacturing. It was found that the key to implement it lies on their people. Findings and practices obtained from the survey, case studies and literature were then consolidated to formulate a framework for implementing lean manufacturing. The framework consists of three major sections which are foundation, improvement practices, and key areas for continuous improvement. An assessment was then carried out to evaluate the framework and the comments given by the evaluators were used to generate an improved framework. This framework provides a comprehensive view of lean manufacturing and gives important guiding principles for implementing it.