Investigating factors that negatively influence lean implementation in the Eastern Cape automotive industry

Abstract

In this intensely competitive environment of the global economy, the survival of even the most established manufacturers depends on their ability to continuously improve quality whilst reducing costs. The resulting productivity of producing more with less is the only key to market leadership and sustainable competitive advantage. Changing production methods from mass-production to Lean Manufacturing has become the essential practise for successful manufacturers (Rogers and Sim, 2009). The purpose of this study is to investigate what factors negate the adoption and implementation of Lean Manufacturing as a means to gain competitive advantage. The focus was on companies that have participated in the AIDC Tirisano cluster programme. The study investigated what effect Organisational Culture, Leadership Behaviours, Employee Involvement and Strategy Integration have on Lean Manufacturing adoption and implementation. This study applied the mixed methodologies of qualitative and quantitative approaches using methodological triangulation. A cross sectional analytical survey approach in a descriptive case study was undertaken. The findings from the questions and the interviews from the respondents who participated in the survey indicated that the practices in some companies enable the successful adoption and implementation of Lean Manufacturing whilst in some others the practices will negatively affect the adoption and implementation. The study concludes by stating that South African automotive component manufacturers are under immense pressure to improve quality and reduce costs. Initiatives like Lean Manufacturing should be undertaken in order to bring about these improvements. But this improvement comes about by changing the current way of doing things. Companies need to undertake a total approach when implementing Lean as part of the business strategy and this must be driven by management as leaders and a team culture that involves all employees needs to be present.

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