Lean Manufacturing Sustainability: A Critical Review of Barriers and its Impact

Abstract

The objective of this research is to explore the challenges in sustaining lean manufacturing practices with in the automotive sector. Lean Manufacturing is widely adopted to improve quality, reduce costs and enhance operational efficiency. However, sustaining these dynamic practices remains a significant challenge. Factors such as management related barriers, workforce resistance, process related and resources related barriers has considerable impact on sustenance of Lean Manufacturing practices. The research explored the sustainability of LM practices by gathering expert insights on 24 influencing factors. A survey was conducted among over 50 automotive industries in Karachi, to examine the challenges associated with management, workforce, process and resource related issues. The collected data was analyzed on SPSS to identify the key obstacle hindering the sustainability of Lean Manufacturing Practices. Findings indicate that while Lean Manufacturing practices are implemented across organizations, sustaining these practices is difficult. The impact of Workforce related, Resource related & Process related barriers was evident but Management related barriers, including lack of leadership support were found to be most influential factor. Employee resistance often stems from inadequate managerial involvement in Lean initiatives. To enhance Lean Manufacturing Practices sustainability, organizations needs to strengthen leadership commitment, provide continuous employee trainings and integrating a mechanism of follow ups and performance tracking. Future research expands the sample size and include multiple industries to gain broader insights into sustainability challenges across various sectors.