Analyzing the Lean Waste in Medium-Scale Size Industries by Lean Practice-Waste Impact Matrix
DOI:
https://doi.org/10.24425/mper.2025.157210Abstract
Today, industries faces ongoing challenges related to the cost and quality of products, delivery, and increased global competition. These challenges have forced the industry to change its strategy, improve product quality, and reduce production costs in order to remain competitive in global markets. One of the most effective strategies for dealing with these challenges is Lean Manufacturing. The aim of this article is to establish a methodology for assessing and identifying the level of implementation of Lean Manufacturing practices in medium-sized industrial enterprises in the dairy industry. The proposed methodology integrates Lean Position Map, Percent Point Score method, and Impact Matrix of Lean Practice–Waste. This methodology classifies and categorizes companies based on the level of implementation of ten common Lean Manufacturing practices and examines the impact of implementing these practices on reducing or eliminating eight types of waste, facilitating the development of an action plan for improvement. The Lean Position Map was applied to evaluate twenty dairy companies located in Baghdad in order to examine and understand the level of implementation of Lean Manufacturing practices in the processes and activities of these companies. A matrix of the impact of Lean Manufacturing practices on waste elimination was developed to understand the impact of ten Lean Manufacturing practices on eight types of waste.References
Al-Baldawi, Z., Kassam, A.E.H., & Al-Zubaidi, S.S.A. (2023). Evaluation of the interrelationships and degree of influence of lean dimensions based on the Fuzzy DEMATEL method. Advances in Science and Technology Research Journal, 17 (4), 215–226.
Al-Baldawi, Z., Kassam, A.H., & Al-Zubaidi, S.S.A. (2024). Evaluation of the level of importance of lean activities in small and medium-sized enterprises using an integrated model based on fuzzy logic. Management and Production Engineering Review, 15 (1)
Al-Baldawi, Z., Sawsan, A.H.K., & Al-Zubaidi, S.A. (2024). Research and evaluation of the level of Lean Manufacturing in small and medium-sezed enterprises using an intergrated fuzzy dematel/fuzzyAHP/ Fuzzy Topsis Model. Management Systems in Production Engineering, 32(4)
Alaskari, O., Ahmad, M.M., & Pinedo-Cuenca, R. (2016). Development of a methodology to assist small and medium-sized manufacturing enterprises in selecting appropriate lean tools. International Journal of Lean Six Sigma, 7 (1)
Ali, B., Jaweed, S., and Fahad, M. (2015). Implementation of a waste assessment matrix and production line balancing to improve efficiency in a high-mix/highvolume manufacturing plant. ESMD Conference Proceedings, Karachi, M (March 2017), 65–75. https: //www.researchgate.net/publication/295806964
Amin, M.A. (2013). A systematic approach to lean strategy selection and lean assessment in manufacturing organizations. In: School of Chemistry, Physics and Mechanical Engineering Faculty of Science and Engineering Queensland University of Technology (March edition).
Bhamu, J., and Sangwan, K. S. (2014). Lean manufacturing: A literature review and research issues. International Journal of Operations and Production Management, 34 (7), 876–940. DOI: 10.1108/IJOPM-08-2012-0315
Caldera, H.T.S., Desha, C., & Dawes, L. (2019). Assessing the factors that promote and hinder the effective implementation of sustainable business practices in lean SMEs. Journal of Cleaner Production, 218 , 575– 590. DOI: 10.1016/j.jclepro.2019.01.239
Dave, P.Y. (2020). The history of lean manufacturing from the perspective of Toyota and Ford. International Journal of Scientific and Engineering Research, 11 (8), 1598–1602. http://www.ijser.org
Del Rocio Quesada, M.C., & Posada, J.G.A. (2019). Implementation of lean manufacturing techniques in the baking industry in Medellin. Gestao e Producao, 26 (2), 1–9. DOI: 10.1590/0104-530X-2505-19
Enaghani, M.R., Arashpour, M.R. and Karimi, M. (2009). The relationship between lean and TPM, Master thesis, University Of Borĺs
Gobinath, S., Elangovan, D., & Dharmalingam, S. (2015). Problems and challenges related to lean manufacturing in the production process – a review. International Journal of ChemTech Research, 8 (1), 45–51.
Medonos, M. (2021). Lean level in manufacturing companies – a study on the implementation of lean manufacturing. Acta Academica Karviniensia, 21 (2), 54–65. DOI: 10.25142/aak.2021.012
Nwanya, S.C., & Oko, A. (2019). Limitations and opportunities for the application of lean continuous process management techniques in the Nigerian manufacturing industry – a review. Journal of Physics: Conference Series, 1378 (2). DOI: 10.1088/1742-6596/1378/2/022086
Posada, A., Botero Herrera, V.E., & Romano Martinez, M.E. (2010). Benchmarking on lean manufacturing in the textile sector in Medellin. Journal of Economics, Finance and Administrative Science, 15 (28), 141–170.
Rahmanasari, D., Sutopo, W., & Rohani, J. M. (2021). Implementation of lean manufacturing process to reduce waste: a case study. IOP Conference Series: Materials Science and Engineering, 1096 (1), 012006. DOI: 10.1088/1757-899x/1096/1/012006
Rahmadianto, R. and Saifuddin, J. A. (2025). Lean manufacturing analysis using the waste assessment model (WAM) to reduce critical waste in the sarong fabric production process at Cv. Xyz. Indonesian Interdisciplinary Journal of Sharia Economics (IIJSE) e-ISSN: 2621-606X, 8 (2), 5650–5663.
Rajpurohit, L. (2017). A study of lean tool selection in the manufacturing sector (November issue). DOI: 10.13140/RG.2.2.30983.50080
Rose, A.N.M. (2011). Best practices in lean manufacturing in SMEs. International Conference on Industrial Engineering and Operations Management, 1 (1), 872–877.
Rose, A.N.M., Deros, B.M., & Rahman, M.N.A. (2013). Perception of lean manufacturing and actual practice among Malaysian SMEs in the automotive industry. International Journal of Automotive and Mechanical Engineering, 7 (1), 820–829. DOI: 10.15282/ijame.7.2012.2.0067
Saini, S., & Singh, D. (2020). A study of the perception of lean manufacturing practices in small and mediumsized enterprises in northern India: An empirical study. Industrial Engineering Journal, 13 (3). DOI: 10.26488/iej.13.3.1218
Soni, S.R. and Narkhede, S.B.E. (2017). Lean Waste & Lean Manufacturing. An international journal dedicated to innovative research in the field of technology, 3 (8), 13–16.
Wei, Y.W. (2019). Conceptual analysis of lean manufacturing (LM) principles for small and medium-sized enterprises (SMEs).
Weldeslassie, H.A., Vermaack, C., Kristos, K., Minwuyelet, L., Tsegay, M., Tekola, N.H., and Gidey, Y. (2019). The contribution of micro, small, and medium-sized enterprises (SMEs) to income generation, employment, and GDP: the case of Ethiopia. Journal of Sustainable Development, 12 (3)
