Critical success factors and barriers of implementing lean manufacturing in precast industry

Abstract

The aim of this research is to study critical success factors (CSFs) and barriers in implementing Lean Manufacturing (LM) and way forward to overcome the identified critical barriers. To address these findings, a methodological approach was implemented in three (3) tiers. First, a comprehensive review on the literature in terms of LM implementation, CSFs and barriers followed was undertaken. Second, an analytic approach was accessed by using a questionnaire which was distributed to a total of 78 number of respondents in the organisation. Third, interview session with four (4) employees was conducted in order to mitigate the perceived barriers. Upon validation of the analysis, the results revealed most of the respondents agreed Leadership and Management Commitment are the key success factors for the organisation to stay competitive. Whilst for the barrier, it is believed that the obstacle to LM implementation is more towards Managerial barrier (i.e. lack of Lean culture, strict requirement and approval, less personal empowerment). Thus, two (2) general directives have been forwarded by the author to overcome the identified barrier which are initiating learning organisation and simplifying Lean process. It is believed this strategy could create awareness and develop Lean culture, besides that the employee able to set a baseline on any discrepancy that may appear in the shop floor. Overall, these findings present a critical view for the organisations to know factors that could drive and restrain them from implementing LM.