Ranking the implementation barriers of manufacturing lean using fuzzy DEMATEL (Case study: Gas Industry)

Authors
Mehdi Ajalli 1
Hossein Safari 2
1 Universiyu of tehran
2 University of Tehran
10.52547/jde.1.3.147
Abstract
After the past of two decades of lean manufacturing (LM) introduction in Iran, instead comparing this concept with industry as a culture, it is used as tool for improvement. Without doubt, LM as one of the most strong of quality improvement systems is countered by barriers and problems. One of main tasks of top management is identification and ranking the LM barriers for comparison by important barriers. This research identifies the key barriers in successful implementation of LM. Although the country researchers to point some implementation barriers of LM, But they have not studied the total literature of these barriers, also the relationship between barriers and finally ranking of them.

For this purpose, after the literature review and interview with experts of gas industry, 7 barriers (as 7 secondary hypotheses of research) were identified in successful implementation of gas industry, and they were confirmed with validity. Then by distribution and gathering of 170 questioners and using statistical tests (Kolmogorov-Smirnov and mean), the main hypothesis of this research and 7 secondary hypotheses were confirmed. Finally, the relationship between barriers and their ranking were studied using fuzzy DEMATEL model. According to this model and done ranking, a practical program was proposed for comparison by implementation barriers of LM in gas industry.
Keywords
Implementation barriers
lean manufacturing
fuzzy DEMATEL
Gas industry
Alavi S. (2003) "Leaning the right way", IEE Manufacturing Engineer, Vol. 82, No.3, pp. 32–35.
Associates, New York, NY.
Baker, P. (2002). “Why is Lean So Far off?” Works Management 55: 26–29.
Bayou, M. E.,de Korvin, A., Measuring the Leanness of Manufacturing Systems: A Case Study of Ford Motor Company and General Motors, Journal of Engineering and Technology Management 2008;25:287.
Bhasin S., (2012) prominent obstacles to Lean"", International Journal of Productivity and Performance Management, Vol. 61 ISSN: 4, pp.403 - 425."
Bhasin, S., and P. Burcher. (2006). “Lean Viewed as a Philosophy.” Journal of Manufacturing Technology Management 17 (1): 56–72.
Blanchard, D. (2007). “Census of U.S. Manufacturers – Lean Green and Low Cost.” Industry Week, October.
Boyle, T. A., M. S. Scherrer-Rathje, and I. Stuart. (2011). “Learning to Be Lean: The Influence of External Information Sources in Lean Improvements.” Journal of Manufacturing Technology Management 22 (5): 587–603.
Business Review, Vol. 72 No. 2, pp. 93-104.
Chang, B. et al., (2011). Fuzzy DEMATEL method for developing supplier selection criteria. Expert Systems with Applications. 38, 1850–1858.
Ciarniene R. & Vienazindiene M. (2012). “Lean manufacturing: theory and practice” Economics and Management, Vol. 17, No.2, pp. 726-732.
Darabi R, Moradi R. & Toomari U. (2012), Barriers to Implementation of Lean Accounting in Manufacturing Companies"", International Journal of Business and Commerce Vol. 1, No. 9, pp 38-51."
Dehkordi, A. et al., (2012). Investigating the Effect of Emotional Intelligence and Personality Traits on Entrepreneurial Intention Using the Fuzzy DEMATEL Method. International Journal of Business and Social Science. 3 (13).
Dixit Abhishek, Patel Sanjay, Dixit Anupam (2011). “Lean Manufacturing to lean enterprises” proceedings of the International Conference on Industrial Engineering held at SVNIT, Surat, November 17-19, 2011, pp-431-435.
Esfandyari Alireza & Osman M.R. (2011). “Success and failure issues to lead lean manufacturing implementation.” proceedings of the International Management Conference, Malaysia, April 16-17, 2011.
Fontela, E., &Gabus, A. (1976). The DEMATEL observer, Battelle Institute, Geneva Research Center.
Hines P. & Taylor D. (2000) "Going Lean”, Lean Enterprise Research Centre, Cardiff Business School, pp. 3 – 43, assessed from www.textmatters.com on 12.12.2013.
Hines P., Holweg M. & Rich N. (2004). "Learning to evolve: A review of contemporary lean thinking", International Journal of Operations & Production Management, Vol. 24 No.10, pp.994-1011.
Jassbi, Javad., Mohamadnejad, Farshid., Nasrollahzadeh, Hossein., (2011), A Fuzzy DEMATEL framework for modeling cause and effect relationships of strategy map, Expert Systems with Applications , 5967–5973.
Lin CJ, Wu WW (2004). A fuzzy extension of the DEMATEL method for group decision making. The proceeding of 1st Operation Research, 156. 445–455.
Losonci, D., K. Demeter, and I. Jenei. (2011). “Factors Influencing Employee Perceptions in Lean Transformations.” International Journal of Production Economics 131: 30–43.
Marodin, G. A., and T. A. Saurin. (2014). “Classification and Relationships between Risks That Affect Lean Production Implementation: A Study in Southern Brazil.” Journal of Manufacturing Technology Management, Forthcoming. doi: 10.1108/JMTM-122012-0113.
Marodin, G. A., and T. A. Saurin. (2015). “Managing barriers to lean production implementations: context matters, INTERNATIONAL JOURNAL OF PRODUCTION RESEARCH, Vol. 53, No. 13, 3947–3962
Marvel, J. H., and C. R. Standridge. (2009). “Simulation-enhanced Lean Design Process.” Journal of Industrial Engineering and Management 2: 90–113.
Moyano-Fuentes, J., and M. Sacristán-Diaz. (2012). “Learning on Lean: A Review of Thinking and Research.” International Journal of Operations & Production Management 32 (5): 551–582.
Nordin N, Baba Md Deros and Dzuraidah Abd Wahab,(2010) A Survey on Lean Manufacturing Implementation in Malaysian Automotive Industry"", International Journal of Innovation, Management and Technology, Vol. 1, No. 4, October 2010 ISSN: 2010-0248 Pp 374-380."
Nordin N. & Deros B. MD (2013). “The barriers to lean manufacturing implementation” accessed from http://www.scribd.com/doc/149637090/THE-BARRIERS-TO-LEAN-MANUFACTURING-IMPLEMENTATION on 12/12/2013.
Opricovic, S., Tzeng, G.H., 2003. Defuzzification within a multicriteria decision model. International Journal of Uncertainty, Fuzziness and Knowledge-based Systems 11, 635–652.
Panizzolo, R., P. Garengo, M. K. Sharma, and A. Gore. (2012). “Lean Manufacturing in Developing Countries: Evidence from Indian SMEs.” Production Planning & Control 23 (10–11): 769–788.
Rakesh Kumar and Vikas Kumar Barriers (2014). “in Implementation of Lean Manufacturing System in Indian industry: A Survey, International Journal of Latest Trends in Engineering and Technology (IJLTET)”, Vol. 4, Issue 2.
Rao, K., Becoming Lean: Inside Stories of US Manufacturers, Monthly Labor Review, 1999;122.
Rose A.M.N., Deros B.Md & Rahman, M.N.Ab. (2010). “Development of framework for lean manufacturing implementation in SME‟s” Asia pacific Industrial Engineering and Management Systems Conference, Melaka, Dec. 7-10, 2010.
Sanda A., et al., (2011), Managerial Competence and Non-Performance of Small Firms in a Developing Economy, International Journal of Contemporary Business Studies 2(3).
Shah, R., and P. T. Ward. (2003). “Lean Manufacturing: Context, Practice Bundles, and Performance.” Journal of Operations Management 21: 129–149.
Singh B., Garg S.K., Sharma S.K, (2010), Scope for Lean implementation: a survey of 127 Indian industries"", International Journal of Rapid Manufacturing, Vol. X, No. Y, pp1-11."
Singh Binod kumar, Bhar Chandan & Pandurangan Visvesvaran (2011). “Competitive advantage of lean manufacturing over traditional manufacturing” proceedings of the International Conference on Industrial Engineering held at SVNIT, Surat. November 17-19, 2011, pp. 442-446.
Teleghani Mohammad (2010). “Key factor for implementing the lean manufacturing system” Journal of American science. Vol.6, No. 7, pp. 287-291.
Turesky, E. F., and P. Connell. (2010). “Off the Rails: Understanding the Derailment of a Lean Manufacturing Initiative.” Organization Management Journal 7 (2): 110–132.
Womack, J. and Jones, D.T. (1994), ‘‘From lean production to the lean enterprise’’, Harvard
Womack, J., Jones, D.T. and Roos, D. (1990), The Machine that Changed the World, Rawson
Wong Y. Cheng, Wong K. Y., Ali A.,(2009), A Study on Lean Manufacturing Implementation in the Malaysian Electrical and Electronics Industry"", European Journal of Scientific Research ISSN 1450-216X Vol.38 No.4, pp 521-535".
Wu, Hung-Yi. 2012. Constructing a strategy map for banking institutions with key performance indicators of the balanced scorecard. Evaluation and Program Planning. 35:303-320
Yang Pingyu A. & Yu B. Yu (2010) “The barriers to SME‟s implementation of Lean production & countermeasures.” International journal of innovation, management & technology. Vol.1, No.2 pp. 220-225.