Planning Aspects
|
Project Selection/ Priorization difficulties |
• No criteria to prioritize the projects |
Sahwan et al. (2012)Sahwan, M. A., Ab Rahman, M. N., & Deros, B. M. (2012). Barriers to implement lean manufacturing in Malaysian automotive industry. Jurnal Teknologi, 59(2), 107-110. http://dx.doi.org/10.11113/jt.v59.2571. http://dx.doi.org/10.11113/jt.v59.2571...
; Mahmutaj et al. (2015)Mahmutaj, L. R., Jusufi, G., Zylfijaj, K., & Grubi, A. K. (2015). The role of quality management practices in improving the efficiency and effectiveness of financial services. Mediterranean Journal of Social Sciences, 6(2), 218-225. http://dx.doi.org/10.5901/mjss.2015.v6n2s5p218. http://dx.doi.org/10.5901/mjss.2015.v6n2...
; Jasti & Kodali (2016)Jasti, N. V. K., & Kodali, R. (2016). An empirical study for implementation of lean principles in Indian manufacturing industry. Benchmarking, 23(1), 183-207. http://dx.doi.org/10.1108/BIJ-11-2013-0101. http://dx.doi.org/10.1108/BIJ-11-2013-01...
. |
16 |
• Lots of projects occurring at the same time, competing Lean System team attention |
Gupta et al. (2013)Gupta, V., Acharya, P., & Patwardhan, M. (2013). A strategic and operational approach to assess the lean performance in radial tyre manufacturing in India: a case based study. International Journal of Productivity and Performance Management, 62(6), 634-651. http://dx.doi.org/10.1108/IJPPM-Jun-2012-0057. http://dx.doi.org/10.1108/IJPPM-Jun-2012...
; Bhasin & Burcher (2006)Bhasin, S., & Burcher, P. (2006). Lean viewed as a philosophy. Journal of Manufacturing Technology Management, 17(1), 56-72. http://dx.doi.org/10.1108/17410380610639506. http://dx.doi.org/10.1108/17410380610639...
; Leme et al. (2016)Leme, J. L., Tortorella, G. L., & Augusto, B. P. (2016). Identification of barriers and critical success factors in lean implementation in micro-sized enterprises. Espacios, 37(5), 1. Retrieved in 2018, July 29, from https://www.researchgate.net/publication/303146759_Identification_of_ barriers_and_critical_success_factors_in_lean_implementation_in_micro-sized_enterprises https://www.researchgate.net/publication...
; Murugesan et al. (2012)Murugesan, T. K., Senthil Kumar, B., & Saravana Kumar, M. (2012). Competitive advantage of World Class Manufacturing System (WCMS): a study of manufacturing companies in South India. European Journal of Soil Science, 29(2), 295-311. Retrieved in 2018, July 29, from https://www.researchgate.net/publication/265797666_Competitive_Advantage_of_World_Class_Manufacturing_System_WCMS_-A_Study_of_Manufacturing_Companies. [_in_South_India.] https://www.researchgate.net/publication...
. |
• Difficulties to conciliate goals for all projects, sometimes compromising medium term goals instead of short term one |
Marodin & Saurin (2015)Marodin, G. A., & Saurin, T. A. (2015). Classification and relationships between risks that affect lean production implementation: a study in southern Brazil. Journal of Manufacturing Technology Management, 26(1), 57-79. http://dx.doi.org/10.1108/JMTM-12-2012-0113. http://dx.doi.org/10.1108/JMTM-12-2012-0...
; Worley & Doolen (2015)Worley, J. M., & Doolen, T. L. (2015). Organizational structure, employee problem solving, and lean implementation. International Journal of Lean Six Sigma, 6(1), 39-58. http://dx.doi.org/10.1108/IJLSS-12-2013-0058. http://dx.doi.org/10.1108/IJLSS-12-2013-...
; Mahmutaj et al. (2015)Mahmutaj, L. R., Jusufi, G., Zylfijaj, K., & Grubi, A. K. (2015). The role of quality management practices in improving the efficiency and effectiveness of financial services. Mediterranean Journal of Social Sciences, 6(2), 218-225. http://dx.doi.org/10.5901/mjss.2015.v6n2s5p218. http://dx.doi.org/10.5901/mjss.2015.v6n2...
. |
Implementation team failures |
• Inadequate team selection |
Dora et al. (2013)Dora, M., Van Goubergen, D., Kumar, M., Molnar, A., & Gellynck, X. (2013). Application of lean practices in small and medium-sized food enterprises. British Food Journal, 116(1), 125-141. http://dx.doi.org/10.1108/BFJ-05-2012-0107. http://dx.doi.org/10.1108/BFJ-05-2012-01...
; Jadhav et al. (2014)Jadhav, R. J., Mantha, S. S., & Rane, B. S. (2014). Exploring barriers in lean implementation. International Journal of Lean Six Sigma, 5(2), 122-148. http://dx.doi.org/10.1108/IJLSS-12-2012-0014. http://dx.doi.org/10.1108/IJLSS-12-2012-...
; Sahwan et al. (2012)Sahwan, M. A., Ab Rahman, M. N., & Deros, B. M. (2012). Barriers to implement lean manufacturing in Malaysian automotive industry. Jurnal Teknologi, 59(2), 107-110. http://dx.doi.org/10.11113/jt.v59.2571. http://dx.doi.org/10.11113/jt.v59.2571...
; Bhasin (2012)Bhasin, S. (2012). Prominent obstacles to lean. International Journal of Productivity and Performance Management, 61(4), 403-425. http://dx.doi.org/10.1108/17410401211212661. http://dx.doi.org/10.1108/17410401211212...
; Pedersen & Huniche (2011)Pedersen, E. R. G., & Huniche, M. (2011). Determinants of lean success and failure in the Danish public sector: a negotiated order perspective. International Journal of Public Sector Management, 24(5), 403-420. http://dx.doi.org/10.1108/09513551111147141. http://dx.doi.org/10.1108/09513551111147...
. |
19 |
• Lack of Lean knowledge |
Jasti & Kodali (2016)Jasti, N. V. K., & Kodali, R. (2016). An empirical study for implementation of lean principles in Indian manufacturing industry. Benchmarking, 23(1), 183-207. http://dx.doi.org/10.1108/BIJ-11-2013-0101. http://dx.doi.org/10.1108/BIJ-11-2013-01...
; Marodin & Saurin (2015)Marodin, G. A., & Saurin, T. A. (2015). Classification and relationships between risks that affect lean production implementation: a study in southern Brazil. Journal of Manufacturing Technology Management, 26(1), 57-79. http://dx.doi.org/10.1108/JMTM-12-2012-0113. http://dx.doi.org/10.1108/JMTM-12-2012-0...
; Dora et al. (2013)Dora, M., Van Goubergen, D., Kumar, M., Molnar, A., & Gellynck, X. (2013). Application of lean practices in small and medium-sized food enterprises. British Food Journal, 116(1), 125-141. http://dx.doi.org/10.1108/BFJ-05-2012-0107. http://dx.doi.org/10.1108/BFJ-05-2012-01...
; Sahwan et al. (2012)Sahwan, M. A., Ab Rahman, M. N., & Deros, B. M. (2012). Barriers to implement lean manufacturing in Malaysian automotive industry. Jurnal Teknologi, 59(2), 107-110. http://dx.doi.org/10.11113/jt.v59.2571. http://dx.doi.org/10.11113/jt.v59.2571...
; Poksinska (2010)Poksinska, B. (2010). The current state of lean implementation in health care: literature review. Quality Management in Health Care, 19(4), 319-329. http://dx.doi.org/10.1097/QMH.0b013e3181fa07bb. PMid:20924253. http://dx.doi.org/10.1097/QMH.0b013e3181...
. |
• Lack of project planning or implementation conduction |
Dora et al. (2013)Dora, M., Van Goubergen, D., Kumar, M., Molnar, A., & Gellynck, X. (2013). Application of lean practices in small and medium-sized food enterprises. British Food Journal, 116(1), 125-141. http://dx.doi.org/10.1108/BFJ-05-2012-0107. http://dx.doi.org/10.1108/BFJ-05-2012-01...
; Mahmutaj et al. (2015)Mahmutaj, L. R., Jusufi, G., Zylfijaj, K., & Grubi, A. K. (2015). The role of quality management practices in improving the efficiency and effectiveness of financial services. Mediterranean Journal of Social Sciences, 6(2), 218-225. http://dx.doi.org/10.5901/mjss.2015.v6n2s5p218. http://dx.doi.org/10.5901/mjss.2015.v6n2...
; Näslund (2013)Näslund, D. (2013). Lean and six sigma: critical success factors revisited. International Journal of Quality and Service Sciences, 5(1), 86-100. http://dx.doi.org/10.1108/17566691311316266. http://dx.doi.org/10.1108/17566691311316...
; Kundu & Murali Manohar (2012)Kundu, G., & Murali Manohar, B. (2012). Critical success factors for implementing lean practices in IT support services. International Journal of Qualitative Research, 6(4), 301-312. Retrieved in 2018, July 29, from http://www.ijqr.net/journal/v6-n4/1.pdf http://www.ijqr.net/journal/v6-n4/1.pdf...
. |
Implementation plan failures |
• Difficulties on implementation follow-up |
Leme et al. (2016)Leme, J. L., Tortorella, G. L., & Augusto, B. P. (2016). Identification of barriers and critical success factors in lean implementation in micro-sized enterprises. Espacios, 37(5), 1. Retrieved in 2018, July 29, from https://www.researchgate.net/publication/303146759_Identification_of_ barriers_and_critical_success_factors_in_lean_implementation_in_micro-sized_enterprises https://www.researchgate.net/publication...
; Noori (2015)Noori, B. (2015). Identifying critical issues in lean implementation in hospitals. Hospital Topics, 93(2), 44-52. http://dx.doi.org/10.1080/00185868.2015.1052299. PMid:26185933. http://dx.doi.org/10.1080/00185868.2015....
; Ihueze and Okpala (2011)Ihueze, C. C., & Okpala, C. C. (2011). A survey of Optimum Manufacturing Strategy as a tool for enhanced industrial revenue. Australian Journal of Basic and Applied Sciences, 5(12), 1321-1329. Retrieved in 2018, July 29, from https://www.researchgate.net/profile/Christopher_ Chukwutoo_Ihueze/publication/266411030_A_Survey_of_Optimum_Manufacturing_Strategy_as_a_Tool_for_Enhanced_Industrial_Revenue/links/5528b9060cf2779ab78e1716/A-Survey-of-Optimum-Manufacturing-Strategy-as-a-Tool-for-Enhanced-Industrial-Revenue.pdf https://www.researchgate.net/profile/Chr...
. |
27 |
• Project action dates are usually being postponed |
Neumann et al. (2015)Neumann, S. L., Mothersell, W. M., & Motwani, J. (2015). The need for implementing lean in the public sector. International Journal of Business Excellence, 8(1), 104-121. http://dx.doi.org/10.1504/IJBEX.2015.065982. http://dx.doi.org/10.1504/IJBEX.2015.065...
; Leme et al. (2016)Leme, J. L., Tortorella, G. L., & Augusto, B. P. (2016). Identification of barriers and critical success factors in lean implementation in micro-sized enterprises. Espacios, 37(5), 1. Retrieved in 2018, July 29, from https://www.researchgate.net/publication/303146759_Identification_of_ barriers_and_critical_success_factors_in_lean_implementation_in_micro-sized_enterprises https://www.researchgate.net/publication...
. |
• Difficulties on measuring financial results |
Marodin & Saurin (2015)Marodin, G. A., & Saurin, T. A. (2015). Classification and relationships between risks that affect lean production implementation: a study in southern Brazil. Journal of Manufacturing Technology Management, 26(1), 57-79. http://dx.doi.org/10.1108/JMTM-12-2012-0113. http://dx.doi.org/10.1108/JMTM-12-2012-0...
; Carmignani & Zammori (2015)Carmignani, G., & Zammori, F. (2015). Lean thinking in the luxury-fashion market. International Journal of Retail & Distribution Management, 43(10-11), 988-1012. http://dx.doi.org/10.1108/IJRDM-07-2014-0093. http://dx.doi.org/10.1108/IJRDM-07-2014-...
; Rees (2014)Rees, G. H. (2014). Organizational readiness and Lean Thinking implementation: findings from three emergency department case studies in New Zealand. Health Services Management Research, 27(1-2), 1-9. http://dx.doi.org/10.1177/0951484814532624. PMid:25595012. http://dx.doi.org/10.1177/09514848145326...
. |
Lack of financial resources |
• Lack of financial resources for layouts redesign and devices or machines acquirements |
Jasti & Kodali (2016)Jasti, N. V. K., & Kodali, R. (2016). An empirical study for implementation of lean principles in Indian manufacturing industry. Benchmarking, 23(1), 183-207. http://dx.doi.org/10.1108/BIJ-11-2013-0101. http://dx.doi.org/10.1108/BIJ-11-2013-01...
; Dora et al. (2013)Dora, M., Van Goubergen, D., Kumar, M., Molnar, A., & Gellynck, X. (2013). Application of lean practices in small and medium-sized food enterprises. British Food Journal, 116(1), 125-141. http://dx.doi.org/10.1108/BFJ-05-2012-0107. http://dx.doi.org/10.1108/BFJ-05-2012-01...
; Marodin & Saurin (2015)Marodin, G. A., & Saurin, T. A. (2015). Classification and relationships between risks that affect lean production implementation: a study in southern Brazil. Journal of Manufacturing Technology Management, 26(1), 57-79. http://dx.doi.org/10.1108/JMTM-12-2012-0113. http://dx.doi.org/10.1108/JMTM-12-2012-0...
; Jadhav et al. (2014)Jadhav, R. J., Mantha, S. S., & Rane, B. S. (2014). Exploring barriers in lean implementation. International Journal of Lean Six Sigma, 5(2), 122-148. http://dx.doi.org/10.1108/IJLSS-12-2012-0014. http://dx.doi.org/10.1108/IJLSS-12-2012-...
; Al-Najem et al. (2013)Al-Najem, M., Dhakal, H., Labib, A., & Bennett, N. (2013). Lean readiness level within Kuwaiti manufacturing industries. International Journal of Lean Six Sigma, 4(3), 280-320. http://dx.doi.org/10.1108/IJLSS-05-2013-0027. http://dx.doi.org/10.1108/IJLSS-05-2013-...
. |
6 |
Layouts/ Product/ Process difficulties |
• New system adaptation is not so clear to a specific product, layout or even process |
Bhasin & Burcher (2006)Bhasin, S., & Burcher, P. (2006). Lean viewed as a philosophy. Journal of Manufacturing Technology Management, 17(1), 56-72. http://dx.doi.org/10.1108/17410380610639506. http://dx.doi.org/10.1108/17410380610639...
; Rose et al. (2014)Rose, A. N. M., Deros, B. M., & Rahman, M. N. A. (2014). Critical success factors for implementing lean manufacturing in Malaysian automotive industry. Research Journal of Applied Sciences, Engineering and Technology, 8(10), 1191-1200. http://dx.doi.org/10.19026/rjaset.8.1084. http://dx.doi.org/10.19026/rjaset.8.1084...
. |
13 |
• Obstacles on new customer / supplier interfaces |
Jasti & Kodali (2016)Jasti, N. V. K., & Kodali, R. (2016). An empirical study for implementation of lean principles in Indian manufacturing industry. Benchmarking, 23(1), 183-207. http://dx.doi.org/10.1108/BIJ-11-2013-0101. http://dx.doi.org/10.1108/BIJ-11-2013-01...
; Jadhav et al. (2014)Jadhav, R. J., Mantha, S. S., & Rane, B. S. (2014). Exploring barriers in lean implementation. International Journal of Lean Six Sigma, 5(2), 122-148. http://dx.doi.org/10.1108/IJLSS-12-2012-0014. http://dx.doi.org/10.1108/IJLSS-12-2012-...
; Sahwan et al. (2012)Sahwan, M. A., Ab Rahman, M. N., & Deros, B. M. (2012). Barriers to implement lean manufacturing in Malaysian automotive industry. Jurnal Teknologi, 59(2), 107-110. http://dx.doi.org/10.11113/jt.v59.2571. http://dx.doi.org/10.11113/jt.v59.2571...
; Mahmutaj et al. (2015)Mahmutaj, L. R., Jusufi, G., Zylfijaj, K., & Grubi, A. K. (2015). The role of quality management practices in improving the efficiency and effectiveness of financial services. Mediterranean Journal of Social Sciences, 6(2), 218-225. http://dx.doi.org/10.5901/mjss.2015.v6n2s5p218. http://dx.doi.org/10.5901/mjss.2015.v6n2...
. |
Interdepartmental conflicts |
• Different goals for each department |
Achanga et al. (2006)Achanga, P., Shehab, E., Roy, R., & Nelder, G. (2006). Critical success factors for lean implementation within SMEs. Journal of Manufacturing Technology Management, 17(4), 460-471. http://dx.doi.org/10.1108/17410380610662889. http://dx.doi.org/10.1108/17410380610662...
; Dammand et al. (2014)Dammand, J., Hørlyck, M., Jacobsen, T. L., Lueg, R., & Röck, R. L. (2014). Lean management in hospitals: evidence from Denmark. Administratie si Management Public, (23), 19-35. Retrieved in 2018, July 29, from http://www.ramp.ase.ro/en/_data/files/articole/2014/23-02.pdf http://www.ramp.ase.ro/en/_data/files/ar...
. |
8 |
• Support areas are not responsible for their actions in the project |
Elnadi & Shehab (2015)Elnadi, M., & Shehab, E. (2015). Main enablers and factors for successful implementation of lean in product-service systems. International Journal of Agile Systems and Management, 8(3-4), 332-354. http://dx.doi.org/10.1504/IJASM.2015.073542. http://dx.doi.org/10.1504/IJASM.2015.073...
, Hwang et al. (2014)Hwang, P., Hwang, D., & Hong, P. (2014). Lean practices for quality results: a case illustration. International Journal of Health Care Quality Assurance, 27(8), 729-741. http://dx.doi.org/10.1108/IJHCQA-03-2014-0024. PMid:25417378. http://dx.doi.org/10.1108/IJHCQA-03-2014...
. |
Human Aspects
|
Lack of employee involvement in project decision |
• Employees are not involved during the project causing reworks and difficulties of implementation |
Costa et al. (2017)Costa, L. B. M., Godinho, M., Fo., Rentes, A. F., Bertani, T. M., & Mardegan, R. (2017). Lean healthcare in developing countries: evidence from Brazilian hospitals. The International Journal of Health Planning and Management, 32(1), e99-e120. http://dx.doi.org/10.1002/hpm.2331. PMid:26681656. http://dx.doi.org/10.1002/hpm.2331...
; Jadhav et al. (2014)Jadhav, R. J., Mantha, S. S., & Rane, B. S. (2014). Exploring barriers in lean implementation. International Journal of Lean Six Sigma, 5(2), 122-148. http://dx.doi.org/10.1108/IJLSS-12-2012-0014. http://dx.doi.org/10.1108/IJLSS-12-2012-...
; Al-Najem et al. (2013)Al-Najem, M., Dhakal, H., Labib, A., & Bennett, N. (2013). Lean readiness level within Kuwaiti manufacturing industries. International Journal of Lean Six Sigma, 4(3), 280-320. http://dx.doi.org/10.1108/IJLSS-05-2013-0027. http://dx.doi.org/10.1108/IJLSS-05-2013-...
; Rossiter Hofer et al. (2011)Rossiter Hofer, A., Hofer, C., Eroglu, C., & Waller, M. A. (2011). An institutional theoretic perspective on forces driving adoption of lean production globally. International Journal of Logistics Management, 22(2), 148-178. http://dx.doi.org/10.1108/09574091111156532. http://dx.doi.org/10.1108/09574091111156...
; Abuhejleh et al. (2016)Abuhejleh, A., Dulaimi, M., & Ellahham, S. (2016). Using lean management to leverage innovation in healthcare projects: case study of a public hospital in the UAE. BMJ Innovations, 2(1), 22-32. http://dx.doi.org/10.1136/bmjinnov-2015-000076. http://dx.doi.org/10.1136/bmjinnov-2015-...
. |
11 |
• Employees’ mindset is not impacted by the project |
Rane et al. (2016)Rane, A. B., Sunnapwar, V. K., & Rane, S. (2016). Strategies to overcome the HR barriers in successful lean implementation. International Journal of Procurement Management, 9(2), 223-247. http://dx.doi.org/10.1504/IJPM.2016.075266. http://dx.doi.org/10.1504/IJPM.2016.0752...
; Marodin and Saurin (2015)Marodin, G. A., & Saurin, T. A. (2015). Classification and relationships between risks that affect lean production implementation: a study in southern Brazil. Journal of Manufacturing Technology Management, 26(1), 57-79. http://dx.doi.org/10.1108/JMTM-12-2012-0113. http://dx.doi.org/10.1108/JMTM-12-2012-0...
. |
Employee insecurity |
• Employees are afraid to be fired after the implementation |
Costa et al. (2017)Costa, L. B. M., Godinho, M., Fo., Rentes, A. F., Bertani, T. M., & Mardegan, R. (2017). Lean healthcare in developing countries: evidence from Brazilian hospitals. The International Journal of Health Planning and Management, 32(1), e99-e120. http://dx.doi.org/10.1002/hpm.2331. PMid:26681656. http://dx.doi.org/10.1002/hpm.2331...
; Jasti & Kodali (2016)Jasti, N. V. K., & Kodali, R. (2016). An empirical study for implementation of lean principles in Indian manufacturing industry. Benchmarking, 23(1), 183-207. http://dx.doi.org/10.1108/BIJ-11-2013-0101. http://dx.doi.org/10.1108/BIJ-11-2013-01...
; Elnadi & Shehab (2015)Elnadi, M., & Shehab, E. (2015). Main enablers and factors for successful implementation of lean in product-service systems. International Journal of Agile Systems and Management, 8(3-4), 332-354. http://dx.doi.org/10.1504/IJASM.2015.073542. http://dx.doi.org/10.1504/IJASM.2015.073...
. |
9 |
• Employees are not confident in execute their new roles |
Costa et al. (2017)Costa, L. B. M., Godinho, M., Fo., Rentes, A. F., Bertani, T. M., & Mardegan, R. (2017). Lean healthcare in developing countries: evidence from Brazilian hospitals. The International Journal of Health Planning and Management, 32(1), e99-e120. http://dx.doi.org/10.1002/hpm.2331. PMid:26681656. http://dx.doi.org/10.1002/hpm.2331...
; Bhasin (2012)Bhasin, S. (2012). Prominent obstacles to lean. International Journal of Productivity and Performance Management, 61(4), 403-425. http://dx.doi.org/10.1108/17410401211212661. http://dx.doi.org/10.1108/17410401211212...
; Hung et al. (2015)Hung, D., Martinez, M., Yakir, M., & Gray, C. (2015). Implementing a lean management system in primary care: facilitators and barriers from the front lines. Quality Management in Health Care, 24(3), 103-108. http://dx.doi.org/10.1097/QMH.0000000000000062. PMid:26115057. http://dx.doi.org/10.1097/QMH.0000000000...
. |
Managerial Aspects
|
Lack of top management support |
• Implementation efforts not recognized by leadership |
Schuh et al (2012)Schuh, G., Potente, T., Bachmann, F., & Nuyken, T. (2012). Lean management in indirect areas: change of company culture supported by methods. Zeitschrift fuer Wirtschaftlichen Fabrikbetrieb, 107(6), 399-403. http://dx.doi.org/10.3139/104.110776. http://dx.doi.org/10.3139/104.110776...
; Bhasin (2012)Bhasin, S. (2012). Prominent obstacles to lean. International Journal of Productivity and Performance Management, 61(4), 403-425. http://dx.doi.org/10.1108/17410401211212661. http://dx.doi.org/10.1108/17410401211212...
. |
22 |
• Lack of leadership guidance during the process |
Rane et al. (2016)Rane, A. B., Sunnapwar, V. K., & Rane, S. (2016). Strategies to overcome the HR barriers in successful lean implementation. International Journal of Procurement Management, 9(2), 223-247. http://dx.doi.org/10.1504/IJPM.2016.075266. http://dx.doi.org/10.1504/IJPM.2016.0752...
; Djassemi (2014)Djassemi, M. (2014). Lean adoption in small manufacturing shops: attributes and challenges. Journal of Technology, Management, and Applied Engineering, 30(1), 2-10. Retrieved in 2018, July 29, from https://cdn.ymaws.com/www.atmae.org/resource/resmgr/articles/djassemi-lean-small-manufact.pdf https://cdn.ymaws.com/www.atmae.org/reso...
. |
• Lack of alignment between the improvement project and business goals |
Zhou (2016)Zhou, B. (2016). Lean principles, practices, and impacts: study on small and medium-sized enterprises (SMEs). Annals of Operations Research, 241(1-2), 457-474. http://dx.doi.org/10.1007/s10479-012-1177-3. http://dx.doi.org/10.1007/s10479-012-117...
; Djassemi (2014)Djassemi, M. (2014). Lean adoption in small manufacturing shops: attributes and challenges. Journal of Technology, Management, and Applied Engineering, 30(1), 2-10. Retrieved in 2018, July 29, from https://cdn.ymaws.com/www.atmae.org/resource/resmgr/articles/djassemi-lean-small-manufact.pdf https://cdn.ymaws.com/www.atmae.org/reso...
. |
• Leadership does not help overcome difficulties during the implementation process |
Costa et al. (2017)Costa, L. B. M., Godinho, M., Fo., Rentes, A. F., Bertani, T. M., & Mardegan, R. (2017). Lean healthcare in developing countries: evidence from Brazilian hospitals. The International Journal of Health Planning and Management, 32(1), e99-e120. http://dx.doi.org/10.1002/hpm.2331. PMid:26681656. http://dx.doi.org/10.1002/hpm.2331...
; Manzouri et al. (2013)Manzouri, M., Nizam Ab Rahman, M., Saibani, N., & Rosmawati Che Mohd Zain, C. (2013). Lean supply chain practices in the Halal food. International Journal of Lean Six Sigma, 4(4), 389-408. http://dx.doi.org/10.1108/IJLSS-10-2012-0011. http://dx.doi.org/10.1108/IJLSS-10-2012-...
. |
Communication obstacles |
• Lack of communication in the organization about the status of the Lean system implementation project |
Jasti & Kodali (2016)Jasti, N. V. K., & Kodali, R. (2016). An empirical study for implementation of lean principles in Indian manufacturing industry. Benchmarking, 23(1), 183-207. http://dx.doi.org/10.1108/BIJ-11-2013-0101. http://dx.doi.org/10.1108/BIJ-11-2013-01...
; Čiarnienė & Vienažindienė (2014)Čiarnienė, R., & Vienažindienė, M. (2014). How to facilitate implementation of lean concept? Mediterranean Journal of Social Sciences, 5(13), 177-183. Retrieved in 2018, July 29, from hub.tw/10.5901/mjss.2014.v5n13p177. |
7 |
• Difficulties to guarantee communication between shifts, departments or organizational levels |
Costa et al. (2017)Costa, L. B. M., Godinho, M., Fo., Rentes, A. F., Bertani, T. M., & Mardegan, R. (2017). Lean healthcare in developing countries: evidence from Brazilian hospitals. The International Journal of Health Planning and Management, 32(1), e99-e120. http://dx.doi.org/10.1002/hpm.2331. PMid:26681656. http://dx.doi.org/10.1002/hpm.2331...
; Zhou (2016)Zhou, B. (2016). Lean principles, practices, and impacts: study on small and medium-sized enterprises (SMEs). Annals of Operations Research, 241(1-2), 457-474. http://dx.doi.org/10.1007/s10479-012-1177-3. http://dx.doi.org/10.1007/s10479-012-117...
; Rees (2014)Rees, G. H. (2014). Organizational readiness and Lean Thinking implementation: findings from three emergency department case studies in New Zealand. Health Services Management Research, 27(1-2), 1-9. http://dx.doi.org/10.1177/0951484814532624. PMid:25595012. http://dx.doi.org/10.1177/09514848145326...
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Lack of training |
• Employees do not receive enough training about Lean techniques |
Costa et al. (2017)Costa, L. B. M., Godinho, M., Fo., Rentes, A. F., Bertani, T. M., & Mardegan, R. (2017). Lean healthcare in developing countries: evidence from Brazilian hospitals. The International Journal of Health Planning and Management, 32(1), e99-e120. http://dx.doi.org/10.1002/hpm.2331. PMid:26681656. http://dx.doi.org/10.1002/hpm.2331...
; Hung et al (2015)Hung, D., Martinez, M., Yakir, M., & Gray, C. (2015). Implementing a lean management system in primary care: facilitators and barriers from the front lines. Quality Management in Health Care, 24(3), 103-108. http://dx.doi.org/10.1097/QMH.0000000000000062. PMid:26115057. http://dx.doi.org/10.1097/QMH.0000000000...
; Jadhav et al. (2014)Jadhav, R. J., Mantha, S. S., & Rane, B. S. (2014). Exploring barriers in lean implementation. International Journal of Lean Six Sigma, 5(2), 122-148. http://dx.doi.org/10.1108/IJLSS-12-2012-0014. http://dx.doi.org/10.1108/IJLSS-12-2012-...
; Dora et al. (2013)Dora, M., Van Goubergen, D., Kumar, M., Molnar, A., & Gellynck, X. (2013). Application of lean practices in small and medium-sized food enterprises. British Food Journal, 116(1), 125-141. http://dx.doi.org/10.1108/BFJ-05-2012-0107. http://dx.doi.org/10.1108/BFJ-05-2012-01...
; Aij et al. (2013)Aij, K. H., Simons, F. E., Widdershoven, G. A. M., & Visse, M. (2013). Experiences of leaders in the implementation of Lean in a teaching hospital: barriers and facilitators in clinical practices: a qualitative study. BMJ Open, 3(10), e003605. http://dx.doi.org/10.1136/bmjopen-2013-003605. PMid:24171938. http://dx.doi.org/10.1136/bmjopen-2013-0...
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25 |
• Employees were not trained for their new roles |
Costa et al. (2017)Costa, L. B. M., Godinho, M., Fo., Rentes, A. F., Bertani, T. M., & Mardegan, R. (2017). Lean healthcare in developing countries: evidence from Brazilian hospitals. The International Journal of Health Planning and Management, 32(1), e99-e120. http://dx.doi.org/10.1002/hpm.2331. PMid:26681656. http://dx.doi.org/10.1002/hpm.2331...
; Hung et al. (2015)Hung, D., Martinez, M., Yakir, M., & Gray, C. (2015). Implementing a lean management system in primary care: facilitators and barriers from the front lines. Quality Management in Health Care, 24(3), 103-108. http://dx.doi.org/10.1097/QMH.0000000000000062. PMid:26115057. http://dx.doi.org/10.1097/QMH.0000000000...
; Jadhav et al. (2014)Jadhav, R. J., Mantha, S. S., & Rane, B. S. (2014). Exploring barriers in lean implementation. International Journal of Lean Six Sigma, 5(2), 122-148. http://dx.doi.org/10.1108/IJLSS-12-2012-0014. http://dx.doi.org/10.1108/IJLSS-12-2012-...
; Dora et al. (2013)Dora, M., Van Goubergen, D., Kumar, M., Molnar, A., & Gellynck, X. (2013). Application of lean practices in small and medium-sized food enterprises. British Food Journal, 116(1), 125-141. http://dx.doi.org/10.1108/BFJ-05-2012-0107. http://dx.doi.org/10.1108/BFJ-05-2012-01...
; Aij et al. (2013)Aij, K. H., Simons, F. E., Widdershoven, G. A. M., & Visse, M. (2013). Experiences of leaders in the implementation of Lean in a teaching hospital: barriers and facilitators in clinical practices: a qualitative study. BMJ Open, 3(10), e003605. http://dx.doi.org/10.1136/bmjopen-2013-003605. PMid:24171938. http://dx.doi.org/10.1136/bmjopen-2013-0...
; Poksinska (2010)Poksinska, B. (2010). The current state of lean implementation in health care: literature review. Quality Management in Health Care, 19(4), 319-329. http://dx.doi.org/10.1097/QMH.0b013e3181fa07bb. PMid:20924253. http://dx.doi.org/10.1097/QMH.0b013e3181...
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Medium management reluctance |
• Managers do not support implementation |
Marodin & Saurin (2015)Marodin, G. A., & Saurin, T. A. (2015). Classification and relationships between risks that affect lean production implementation: a study in southern Brazil. Journal of Manufacturing Technology Management, 26(1), 57-79. http://dx.doi.org/10.1108/JMTM-12-2012-0113. http://dx.doi.org/10.1108/JMTM-12-2012-0...
; Jadhav et al. (2014)Jadhav, R. J., Mantha, S. S., & Rane, B. S. (2014). Exploring barriers in lean implementation. International Journal of Lean Six Sigma, 5(2), 122-148. http://dx.doi.org/10.1108/IJLSS-12-2012-0014. http://dx.doi.org/10.1108/IJLSS-12-2012-...
; Aij et al. (2013)Aij, K. H., Simons, F. E., Widdershoven, G. A. M., & Visse, M. (2013). Experiences of leaders in the implementation of Lean in a teaching hospital: barriers and facilitators in clinical practices: a qualitative study. BMJ Open, 3(10), e003605. http://dx.doi.org/10.1136/bmjopen-2013-003605. PMid:24171938. http://dx.doi.org/10.1136/bmjopen-2013-0...
; Pedersen & Huniche (2011)Pedersen, E. R. G., & Huniche, M. (2011). Determinants of lean success and failure in the Danish public sector: a negotiated order perspective. International Journal of Public Sector Management, 24(5), 403-420. http://dx.doi.org/10.1108/09513551111147141. http://dx.doi.org/10.1108/09513551111147...
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16 |
• Lack of commitment of management to the project |
Dora et al. (2013)Dora, M., Van Goubergen, D., Kumar, M., Molnar, A., & Gellynck, X. (2013). Application of lean practices in small and medium-sized food enterprises. British Food Journal, 116(1), 125-141. http://dx.doi.org/10.1108/BFJ-05-2012-0107. http://dx.doi.org/10.1108/BFJ-05-2012-01...
; Jadhav et al. (2014)Jadhav, R. J., Mantha, S. S., & Rane, B. S. (2014). Exploring barriers in lean implementation. International Journal of Lean Six Sigma, 5(2), 122-148. http://dx.doi.org/10.1108/IJLSS-12-2012-0014. http://dx.doi.org/10.1108/IJLSS-12-2012-...
; Aij et al (2013)Aij, K. H., Simons, F. E., Widdershoven, G. A. M., & Visse, M. (2013). Experiences of leaders in the implementation of Lean in a teaching hospital: barriers and facilitators in clinical practices: a qualitative study. BMJ Open, 3(10), e003605. http://dx.doi.org/10.1136/bmjopen-2013-003605. PMid:24171938. http://dx.doi.org/10.1136/bmjopen-2013-0...
; Al-Najem et al. (2013)Al-Najem, M., Dhakal, H., Labib, A., & Bennett, N. (2013). Lean readiness level within Kuwaiti manufacturing industries. International Journal of Lean Six Sigma, 4(3), 280-320. http://dx.doi.org/10.1108/IJLSS-05-2013-0027. http://dx.doi.org/10.1108/IJLSS-05-2013-...
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• Managers do not believe in project results |
Jasti & Kodali (2016)Jasti, N. V. K., & Kodali, R. (2016). An empirical study for implementation of lean principles in Indian manufacturing industry. Benchmarking, 23(1), 183-207. http://dx.doi.org/10.1108/BIJ-11-2013-0101. http://dx.doi.org/10.1108/BIJ-11-2013-01...
; Rossiter Hofer et al. (2011)Rossiter Hofer, A., Hofer, C., Eroglu, C., & Waller, M. A. (2011). An institutional theoretic perspective on forces driving adoption of lean production globally. International Journal of Logistics Management, 22(2), 148-178. http://dx.doi.org/10.1108/09574091111156532. http://dx.doi.org/10.1108/09574091111156...
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Cultural Aspects
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Implementation sustainable problems |
• At first obstacles, employees return to old practices or culture; |
Marodin & Saurin (2015)Marodin, G. A., & Saurin, T. A. (2015). Classification and relationships between risks that affect lean production implementation: a study in southern Brazil. Journal of Manufacturing Technology Management, 26(1), 57-79. http://dx.doi.org/10.1108/JMTM-12-2012-0113. http://dx.doi.org/10.1108/JMTM-12-2012-0...
; Bhasin (2012)Bhasin, S. (2012). Prominent obstacles to lean. International Journal of Productivity and Performance Management, 61(4), 403-425. http://dx.doi.org/10.1108/17410401211212661. http://dx.doi.org/10.1108/17410401211212...
; Neumann et al. (2015)Neumann, S. L., Mothersell, W. M., & Motwani, J. (2015). The need for implementing lean in the public sector. International Journal of Business Excellence, 8(1), 104-121. http://dx.doi.org/10.1504/IJBEX.2015.065982. http://dx.doi.org/10.1504/IJBEX.2015.065...
; McLean et al. (2017)McLean, R. S., Antony, J., & Dahlgaard, J. J. (2017). Failure of Continuous Improvement initiatives in manufacturing environments: a systematic review of the evidence. Total Quality Management & Business Excellence, 28(3-4), 219-237. http://dx.doi.org/10.1080/14783363.2015.1063414. http://dx.doi.org/10.1080/14783363.2015....
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13 |
• No follow-up to guarantee new practices |
Costa et al. (2017)Costa, L. B. M., Godinho, M., Fo., Rentes, A. F., Bertani, T. M., & Mardegan, R. (2017). Lean healthcare in developing countries: evidence from Brazilian hospitals. The International Journal of Health Planning and Management, 32(1), e99-e120. http://dx.doi.org/10.1002/hpm.2331. PMid:26681656. http://dx.doi.org/10.1002/hpm.2331...
; Manzouri et al. (2013)Manzouri, M., Nizam Ab Rahman, M., Saibani, N., & Rosmawati Che Mohd Zain, C. (2013). Lean supply chain practices in the Halal food. International Journal of Lean Six Sigma, 4(4), 389-408. http://dx.doi.org/10.1108/IJLSS-10-2012-0011. http://dx.doi.org/10.1108/IJLSS-10-2012-...
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• New practices are only performed with the eyes of the Lean team/management, after that everything returns to the old ones. |
Vinodh & Joy (2012)Vinodh, S., & Joy, D. (2012). Structural equation modelling of lean manufacturing practices. International Journal of Production Research, 50(6), 1598-1607. http://dx.doi.org/10.1080/00207543.2011.560203. http://dx.doi.org/10.1080/00207543.2011....
; Achanga et al. (2006)Achanga, P., Shehab, E., Roy, R., & Nelder, G. (2006). Critical success factors for lean implementation within SMEs. Journal of Manufacturing Technology Management, 17(4), 460-471. http://dx.doi.org/10.1108/17410380610662889. http://dx.doi.org/10.1108/17410380610662...
; Nahmens & Mullens (2011)Nahmens, I., & Mullens, M. A. (2011). Lean homebuilding: lessons learned from a precast concrete panelizer. Journal of Architectural Engineering, 17(4), 155-161. http://dx.doi.org/10.1061/(ASCE)AE.1943-5568.0000037. http://dx.doi.org/10.1061/(ASCE)AE.1943-...
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Cultural differences |
• Difficulties to adapt elements from Lean System as discipline, long term vision and others to a different organizational culture. |
Jadhav et al. (2014)Jadhav, R. J., Mantha, S. S., & Rane, B. S. (2014). Exploring barriers in lean implementation. International Journal of Lean Six Sigma, 5(2), 122-148. http://dx.doi.org/10.1108/IJLSS-12-2012-0014. http://dx.doi.org/10.1108/IJLSS-12-2012-...
; Sahwan et al. (2012)Sahwan, M. A., Ab Rahman, M. N., & Deros, B. M. (2012). Barriers to implement lean manufacturing in Malaysian automotive industry. Jurnal Teknologi, 59(2), 107-110. http://dx.doi.org/10.11113/jt.v59.2571. http://dx.doi.org/10.11113/jt.v59.2571...
; Bhasin (2012)Bhasin, S. (2012). Prominent obstacles to lean. International Journal of Productivity and Performance Management, 61(4), 403-425. http://dx.doi.org/10.1108/17410401211212661. http://dx.doi.org/10.1108/17410401211212...
; Pedersen & Huniche (2011)Pedersen, E. R. G., & Huniche, M. (2011). Determinants of lean success and failure in the Danish public sector: a negotiated order perspective. International Journal of Public Sector Management, 24(5), 403-420. http://dx.doi.org/10.1108/09513551111147141. http://dx.doi.org/10.1108/09513551111147...
; Sisson & Elshennawy (2015)Sisson, J., & Elshennawy, A. (2015). Achieving success with Lean. International Journal of Lean Six Sigma, 6(3), 263-280. http://dx.doi.org/10.1108/IJLSS-07-2014-0024. http://dx.doi.org/10.1108/IJLSS-07-2014-...
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8 |