Prioritizing the solutions of lean implementation in SMEs to overcome its barriers

Abstract

Purpose The implementation of lean production in small manufacturing enterprises (SMEs) harbors a great deal of barriers on practical, theoretical, financial and organizational sides. In view of this, the purpose of this paper is to explore and prioritize the solutions to overcome these barriers and pitfalls in order to identify a list of the most feasible and efficient solutions on which SMEs must focus to success their lean journey. Design/methodology/approach First, a review of the published articles along with the interview of some lean experts have allowed to identify 20 barriers grouped into five categories along with 17 solutions proposed to overcome these barriers. Afterwards, an integrated fuzzy Analytic Hierarchy Process-Technique for Order Preference by Similarity to Ideal Solution (AHP-TOPSIS) was proposed to evaluate and rank the solutions of lean implementation in SMEs and overcome its barriers. The AHP is used to determine weights of the barriers as criteria, and the fuzzy TOPSIS method is used to determine the final ranking of the solutions of lean adoption in SMEs. Findings The top five barriers of lean implementation in SMEs were found to be: lack of management involvement, lack of adapted methodology of lean implementation, short-term vision, fear and resistance to change and lack of understanding of lean. Moreover, the top five solutions to overcome the barriers of lean adoption in SMEs are as follows: commitment and participation of management, adoption of simple measurement and KPIs, development of organizational learning culture, early deployment of lean culture through training and allocation of sufficient time and resources for change. Originality/value The findings of this study can provide a basis for researchers and practitioners in order to understand the real reasons of lean failure in SMEs and develop improvement plans to increase its success rate. Moreover, it proposes a more reliable, robust and systematic decision support tool for stepwise implementation of the solutions of lean adoption in SMEs since they lack sufficient resources to address all the solutions simultaneously.