Application of lean manufacturing in a small-scale manufacturing plant for performance enhancement

Abstract

This study evaluates the readiness of Esabah Enterprise, a small-scale manufacturing plant in Bangladesh, to implement lean manufacturing techniques. The primary objectives are to assess employee engagement, performance evaluation, operational efficiency, and resource adequacy to determine practical lean adoption strategies. SMEs play a crucial role in economic growth and job creation but often struggle with competitiveness and productivity. Structured interviews with key stakeholders at Esabah Enterprise are used to gather qualitative data, analyzed thematically to understand current production processes, performance indicators, staff involvement, and resource availability. The theoretical framework is based on lean manufacturing principles, focusing on waste reduction, process optimization, and continuous improvement. Findings indicate that while Esabah Enterprise generally has sufficient raw materials and equipment, there are issues with timely and quality supply. Enhancements in workplace organization and manpower are needed to improve operational efficiency. Current performance indicators focus on production volume and product quality, lacking continuous monitoring. Low employee involvement in process improvement highlights the need for incentive and training programs. Addressing these issues could significantly enhance the plant's readiness for lean manufacturing. The study offers valuable insights into the opportunities and challenges of implementing lean manufacturing in Bangladeshi small-scale manufacturing facilities. Recommendations identify areas for improvement, providing a roadmap for successful lean adoption and improving understanding of lean readiness in similar environments. While the study’s focus on a single manufacturing site may limit its broader applicability, future research should include more participants and statistical data to provide a comprehensive understanding of lean manufacturing implementation. To mitigate potential biases from qualitative data, future research should incorporate quantitative metrics and diverse data collection methods. The study's findings underscore the need for additional personnel, better resources, improved staff performance evaluation methods, and higher employee participation. Implementing these recommendations could significantly enhance operational performance, efficiency, and competitiveness for Esabah Enterprise and similar small-scale manufacturing facilities. Practical steps include developing thorough training programs, establishing robust supplier relationships, implementing continuous monitoring systems, and fostering a culture of collaboration and continuous improvement.