VALIDATION OF LEAN MANUFACTURING MEASUREMENT INSTRUMENT
DOI:
https://doi.org/10.32890/jtom2015.10.2.2Abstract
This study is intended to provide a valid and reliable measurement instrument for lean manufacturing practices. It is important as lack of consensus regarding the valid and comprehensive measure of lean manufacturing implementation was observed in lean manufacturing literature. 182 large and discrete process manufacturers in Indonesia were involved in this study. A structural equation modeling approach was applied to validate the instrument. The study led to the conclusion that the measurement instrument is valid and reliable. In addition, the study suggested that lean manufacturing practices should be implemented holistically and simultaneously because they are interdependent.
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References
Agus, A., & Hajinoor, M. S. (2012). Lean production supply chain management as driver towards enhancing product quality and business performance: Case study of manufacturing companies in Malaysia. International Journal of Quality & Reliability Management, 29(1), 92 - 121. doi: 10.1108/02656711211190891
Ahmad, S., Schroeder, R. G., & Sinha, K. K. (2003). The role of infrastructure practices in the effectiveness of JIT practices: implications for plant competitiveness. Journal of Engineering Technology Management, 20, 161-191. doi: 10.1016/S0923-4748(03)00017-1
Ahuja, I. P. S., & Khanba, J. S. (2007). An evaluation of TPM initiatives in Indian industry for enhanced manufacturing performance. International Journal of Quality & Reliability Management, 25(2), 147-172. doi: 10.1108/02656710810846925
Arif-Uz-Zaman, K., & Ahsan, A. M. M. N. (2014). Lean supply chain performance measurement. International Journal of Productivity and Performance Management, 63(5), 588-612. doi: 10.1108/ijppm-05-2013-0092
Bagozzi, R. P., & Yi, Y. (1988). On the evaluation of structural equation models. Journal of the Academy of Marketing Science, 16(1), 74-94. doi: 10.1007/BF02723327
Bandalos, D. L., & Finney, S. J. (2009). Item parceling issues in structural equation modeling. In G. A. Marcoulides & R. E.Schumacker (Eds.), New developments and techniques in structural equation modeling (pp. 269-296). Mahwah, NJ: Lawrence Erlbaum Associates, Inc.
Bartezzaghi, E., & Turco, F. (1989). The impact of the just-in-time approach on production system performance: An analytical framework. International Journal of Operation & Production Management, 9(9), 40-61. doi: 10.1108/EUM0000000001257
Belekoukias, I., Garza-Reyes, J. A., & Kumar, V. (2014). The impact of lean methods and tools on the operational performance of manufacturing organisations. International Journal of Production Research, 1-21. doi: 10.1080/00207543.2014.903348
Bou-Llusar, J. C., Escrig-Tena, A. B., Roca-Puig, V., & Beltran-Martin, I. (2009). An empirical assessment of the EFQM excellence model: Evaluation as a TQM framework relative to the MBNQA model. Journal of Operations Management, 27(1), 1-22. doi: 10.1016/j.jom.2008.04.001
Chavez, R., Gimenez, C., Fynes, B., Wiengarten, F., & Yu, W. (2013). Internal lean practices and operational performance: The contingency perspective of industry clockspeed. International Journal of Operations & Production Management, 33(5), 562-588. doi: 10.1108/01443571311322724
Chen, F., Curran, P. J., Bollen, K. A., Kirby, J., & Paxton, P. (2008). An empirical evaluation of the use of fixed cutoff points in RMSEA test statistic in structural equation models. Sociol Methods Res, 36(4), 462-494. doi: 10.1177/0049124108314720
Cheng, T. C. E., & Podolsky, S. (1993). Just-in-time manufacturing: An introduction (1st ed.). Suffolk: Chapman & Hall.
Coffman, D. L., & MacCallum, R. C. (2005). Using parcels to convert path analysis models into latent variable models. Multivariate Behavioral Research, 40(2), 235–259.
Coleman, B. J., & Vaghefi, M. R. (1994). Heijunka?: A key to the Toyota production system. Production and Inventory Management Journal, 35(4), 31-35.
Curran, P. J., West, S. G., & Finch, J. F. (1996). The robustness of test statistics to nonnormality and specification error in confirmatory factor analysis. Psychological Methods, 1(1), 16-29. doi: 10.1037/1082-989X.1.1.16
Dal Pont, G., Furlan, A., & Vinelli, A. (2008). Interrelationships among lean bundles and their effects on operational performance. Operations Management Research, 1, 150-158. doi: 10.1007/s12063-008-0010-2
de Vaus, D. (2002). Surveys in social research (5th ed.). London: Routledge.
Feld, W. M. (2001). Lean manufacturing : tools, techniques, and how to use them. Florida: St. Lucie Press.
Finch, B. J. (2008). Operations now, supply chain profitability and performance (3rd ed.). New York: McGraw Hill/Irwin.
Fullerton, R. R., & Wempe, W. F. (2009). Lean manufacturing, non-financial performance measures, and financial performance. International Journal of Operations & Production Management, 29(3), 214-240. doi: 10.1108/01443570910938970
Furlan, A., Vinelli, A., & Dal Pont, G. (2011). Complementarity and lean manufacturing bundles: an empirical analysis. International Journal of Operations & Production Management, 31(8), 835-850. doi: 10.1108/01443571111153067
Hadid, W., & Mansouri, S. A. (2014). The lean-performance relationship in services: A theoretical model. International Journal of Operations & Production Management, 34(6), 750-785. doi: 10.1108/IJOPM-02-2013-0080
Hair, J. F., Black, W. C., Babin, B. J., & Anderson, R. E. (2010). Multivariate data analysis: A global perspective (7th ed.). New Jersey: Pearson Education, Inc.
Heizer, J., & Render, B. (2011). Operations management (10th ed.). New Jersey: Pearson Education, Inc.
Hirano, H. (1989). JIT factory revolution: A pictorial guide to factory design of the future (7th ed.). Massachusetts: Productivity Press.
Hofer, C., Eroglu, C., & Hofer, A. R. (2012). The effect of lean production on financial performance: The mediating role of inventory leanness. International Journal of Production Economics, 138, 242–253. doi: 10.1016/j.ijpe.2012.03.025
Hu, L.-t., & Bentler, P. M. (1998). Fit indices in covariance structure modeling: Sensitivity to underparameterized model misspecification. Psychological Methods, 3(4), 424-453. doi: 10.1037/1082-989X.3.4.424
Jones, D. T. (2006). Heijunka: Leveling production. Manufacturing Engineering, 137(2), 29-35.
Khanchanapong, T., Prajogo, D., Sohal, A. S., Cooper, B. K., Yeung, A. C. L., & Cheng, T. C. E. (2014). The unique and complementary effects of manufacturing technologies and lean practices on manufacturing operational performance. International Journal of Production Economics, 153, 191-203. doi: 10.1016/j.ijpe.2014.02.021
Kimberlin, C. L., & Winterstein, A. G. (2008). Validity and reliability of measurement instruments used in research. American Journal of Health-System Pharmacy, 65(23), 2276-2284. doi: 10.2146/ajhp070364
Krosnick, J. A. (1991). Response strategies for coping with the cognitive demands of attitude measures in surveys. Applied Cognitive Psychology, 5, 213-236. doi: 10.1002/acp.2350050305
Krosnick, J. A., & Fabrigar, L. R. (1991). Designing rating scales for effective measurement in in surveys. In B. Lyberg, P. Collins, M. D. Leeuw, E. Dippo & C. S. N. (Eds.), Survey measurement and process quality. New York: John Wiley & Sons, Inc.
Milgrom, P., & Roberts, J. (1990). The economics of modern manufacturing: Technology, strategy, and organization. The American Economic Review, 80(3), 511-528.
Milgrom, P., & Roberts, J. (1995). Complementarities and fit strategy, structure, and organizational change in manufacturing. Journal of Accounting and Economics, 19, 179-208. doi: 10.1016/0165-4101(94)00382-F
Nawanir, G., Lim, K. T., & Othman, S. N. (2013). Impact of lean practices on operations performance and business performance: some evidence from Indonesian manufacturing companies. Journal of Manufacturing Technology Management, 24(7), 1019-1050. doi: 10.1108/JMTM-03-2012-0027
Nawanir, G., Lim, K. T., & Othman, S. N. (2015). Measurement instrument for lean manufacturing. International Journal of Applied Science and Technology, 5(4), 102-111.
Nawanir, G., Lim, K. T., & Othman, S. N. (In Press). Lean manufacturing practices in Indonesian manufacturing firms: Are there business performance effects? International Journal of Lean Six Sigma, 7(1).
Nawanir, G., Othman, S. N., & Lim, K. T. (2010). The impact of lean manufacturing practices on operations performance: A study on Indonesian manufacturing companies. Journal of Technology and Operations Management, 5(2), 39-51.
Ohno, T. (1988). The Toyota production system: Beyond large-scale production. Portland, OR: Productivity Press.
Papadopoulou, T. C., & Özbayrak, M. (2005). Leanness: experiences from the journey to date. General review, 16(7), 784-807. doi: 10.1108/17410380510626196
Pettersen, J. (2009). Defining lean production: some conceptual and practical issues. The TQM Journal, 21(2), 127-142. doi: 10.1108/17542730910938137
Podsakoff, P. M., MacKenzie, S. B., Lee, J.-Y., & Podsakoff, N. P. (2003). Common method biases in behavioral research: A critical review of the literature and recommended remedies. Journal of Applied Psychology, 88(5), 879–903. doi: 10.1037/0021-9010.88.5.879
Ramarapu, N. K., Mehra, S., & Frolick, M. N. (1995). A comparative analysis and review of JIT “implementation†research. International Journal of Operations & Production Management, 15(1), 38-49. doi: 10.1108/01443579510077188
Russell, R. S., & Taylor, B. W. (2011). Operations management, creating value a long the supply chain (7th ed.). New Jersey: John Willey & Sons, Inc.
Sakakibara, S., Flynn, B. B., & Schroeder, R. G. (1993). A framework and measurement instrument for just-in-time manufacturing. Production and Operations Management, 2(3), 177-194. doi: 10.1111/j.1937-5956.1993.tb00097.x
Sakakibara, S., Flynn, B. B., Schroeder, R. G., & Morris, W. T. (1997). The impact of just-in-time manufacturing and its infrastructure on manufacturing performance. Management Science, 43(9), 1246-1257.
Sekaran, U., & Bougie, R. (2009). Research methods for business: A skill building approach (5th ed.). West Sussex, United Kingdom: John Willey & Sons Ltd.
Shah, R., & Ward, P. T. (2003). Lean manufacturing: Context, practice bundles, and performance. Journal of Operations Management, 21, 129-149. doi: 10.1016/S0272-6963(02)00108-0
Shah, R., & Ward, P. T. (2007). Defining and developing measures of lean production. Journal of Operations Management, 25, 785-805. doi: 10.1016/j.jom.2007.01.019
Singh, G., & Ahuja, I. S. (2014). An evaluation of just in time (JIT) implementation on manufacturing performance in Indian industry. Journal of Asia Business Studies, 8(3), 278-294. doi: 10.1108/jabs-09-2013-0051
Slack, N., Chambers, S., & Johnston, R. (2010). Operations management (6th ed.). England: Pearson Education Ltd.
Stevenson, W. J. (2012). Operations management (11th ed.). New York: McGraw-Hill/Irwin.
Thanki, S. J., & Thakkar, J. (2014). Status of lean manufacturing practices in Indian industries and government initiatives: A pilot study. Journal of Manufacturing Technology Management, 25(1), 655-675. doi: 10.1108/JMTM-05-2012-0057
West, S. G., Finch, J. F., & Curran, P. J. (1995). Structural equation models with nonnormal variables: Problems and remedies. In R. H. Hoyle (Ed.), Structural equation modeling: Concepts, issues, and applications (pp. 56-75). Thousand Oaks, CA: Sage Publications, Inc.
Ahmad, S., Schroeder, R. G., & Sinha, K. K. (2003). The role of infrastructure practices in the effectiveness of JIT practices: implications for plant competitiveness. Journal of Engineering Technology Management, 20, 161-191. doi: 10.1016/S0923-4748(03)00017-1
Ahuja, I. P. S., & Khanba, J. S. (2007). An evaluation of TPM initiatives in Indian industry for enhanced manufacturing performance. International Journal of Quality & Reliability Management, 25(2), 147-172. doi: 10.1108/02656710810846925
Arif-Uz-Zaman, K., & Ahsan, A. M. M. N. (2014). Lean supply chain performance measurement. International Journal of Productivity and Performance Management, 63(5), 588-612. doi: 10.1108/ijppm-05-2013-0092
Bagozzi, R. P., & Yi, Y. (1988). On the evaluation of structural equation models. Journal of the Academy of Marketing Science, 16(1), 74-94. doi: 10.1007/BF02723327
Bandalos, D. L., & Finney, S. J. (2009). Item parceling issues in structural equation modeling. In G. A. Marcoulides & R. E.Schumacker (Eds.), New developments and techniques in structural equation modeling (pp. 269-296). Mahwah, NJ: Lawrence Erlbaum Associates, Inc.
Bartezzaghi, E., & Turco, F. (1989). The impact of the just-in-time approach on production system performance: An analytical framework. International Journal of Operation & Production Management, 9(9), 40-61. doi: 10.1108/EUM0000000001257
Belekoukias, I., Garza-Reyes, J. A., & Kumar, V. (2014). The impact of lean methods and tools on the operational performance of manufacturing organisations. International Journal of Production Research, 1-21. doi: 10.1080/00207543.2014.903348
Bou-Llusar, J. C., Escrig-Tena, A. B., Roca-Puig, V., & Beltran-Martin, I. (2009). An empirical assessment of the EFQM excellence model: Evaluation as a TQM framework relative to the MBNQA model. Journal of Operations Management, 27(1), 1-22. doi: 10.1016/j.jom.2008.04.001
Chavez, R., Gimenez, C., Fynes, B., Wiengarten, F., & Yu, W. (2013). Internal lean practices and operational performance: The contingency perspective of industry clockspeed. International Journal of Operations & Production Management, 33(5), 562-588. doi: 10.1108/01443571311322724
Chen, F., Curran, P. J., Bollen, K. A., Kirby, J., & Paxton, P. (2008). An empirical evaluation of the use of fixed cutoff points in RMSEA test statistic in structural equation models. Sociol Methods Res, 36(4), 462-494. doi: 10.1177/0049124108314720
Cheng, T. C. E., & Podolsky, S. (1993). Just-in-time manufacturing: An introduction (1st ed.). Suffolk: Chapman & Hall.
Coffman, D. L., & MacCallum, R. C. (2005). Using parcels to convert path analysis models into latent variable models. Multivariate Behavioral Research, 40(2), 235–259.
Coleman, B. J., & Vaghefi, M. R. (1994). Heijunka?: A key to the Toyota production system. Production and Inventory Management Journal, 35(4), 31-35.
Curran, P. J., West, S. G., & Finch, J. F. (1996). The robustness of test statistics to nonnormality and specification error in confirmatory factor analysis. Psychological Methods, 1(1), 16-29. doi: 10.1037/1082-989X.1.1.16
Dal Pont, G., Furlan, A., & Vinelli, A. (2008). Interrelationships among lean bundles and their effects on operational performance. Operations Management Research, 1, 150-158. doi: 10.1007/s12063-008-0010-2
de Vaus, D. (2002). Surveys in social research (5th ed.). London: Routledge.
Feld, W. M. (2001). Lean manufacturing : tools, techniques, and how to use them. Florida: St. Lucie Press.
Finch, B. J. (2008). Operations now, supply chain profitability and performance (3rd ed.). New York: McGraw Hill/Irwin.
Fullerton, R. R., & Wempe, W. F. (2009). Lean manufacturing, non-financial performance measures, and financial performance. International Journal of Operations & Production Management, 29(3), 214-240. doi: 10.1108/01443570910938970
Furlan, A., Vinelli, A., & Dal Pont, G. (2011). Complementarity and lean manufacturing bundles: an empirical analysis. International Journal of Operations & Production Management, 31(8), 835-850. doi: 10.1108/01443571111153067
Hadid, W., & Mansouri, S. A. (2014). The lean-performance relationship in services: A theoretical model. International Journal of Operations & Production Management, 34(6), 750-785. doi: 10.1108/IJOPM-02-2013-0080
Hair, J. F., Black, W. C., Babin, B. J., & Anderson, R. E. (2010). Multivariate data analysis: A global perspective (7th ed.). New Jersey: Pearson Education, Inc.
Heizer, J., & Render, B. (2011). Operations management (10th ed.). New Jersey: Pearson Education, Inc.
Hirano, H. (1989). JIT factory revolution: A pictorial guide to factory design of the future (7th ed.). Massachusetts: Productivity Press.
Hofer, C., Eroglu, C., & Hofer, A. R. (2012). The effect of lean production on financial performance: The mediating role of inventory leanness. International Journal of Production Economics, 138, 242–253. doi: 10.1016/j.ijpe.2012.03.025
Hu, L.-t., & Bentler, P. M. (1998). Fit indices in covariance structure modeling: Sensitivity to underparameterized model misspecification. Psychological Methods, 3(4), 424-453. doi: 10.1037/1082-989X.3.4.424
Jones, D. T. (2006). Heijunka: Leveling production. Manufacturing Engineering, 137(2), 29-35.
Khanchanapong, T., Prajogo, D., Sohal, A. S., Cooper, B. K., Yeung, A. C. L., & Cheng, T. C. E. (2014). The unique and complementary effects of manufacturing technologies and lean practices on manufacturing operational performance. International Journal of Production Economics, 153, 191-203. doi: 10.1016/j.ijpe.2014.02.021
Kimberlin, C. L., & Winterstein, A. G. (2008). Validity and reliability of measurement instruments used in research. American Journal of Health-System Pharmacy, 65(23), 2276-2284. doi: 10.2146/ajhp070364
Krosnick, J. A. (1991). Response strategies for coping with the cognitive demands of attitude measures in surveys. Applied Cognitive Psychology, 5, 213-236. doi: 10.1002/acp.2350050305
Krosnick, J. A., & Fabrigar, L. R. (1991). Designing rating scales for effective measurement in in surveys. In B. Lyberg, P. Collins, M. D. Leeuw, E. Dippo & C. S. N. (Eds.), Survey measurement and process quality. New York: John Wiley & Sons, Inc.
Milgrom, P., & Roberts, J. (1990). The economics of modern manufacturing: Technology, strategy, and organization. The American Economic Review, 80(3), 511-528.
Milgrom, P., & Roberts, J. (1995). Complementarities and fit strategy, structure, and organizational change in manufacturing. Journal of Accounting and Economics, 19, 179-208. doi: 10.1016/0165-4101(94)00382-F
Nawanir, G., Lim, K. T., & Othman, S. N. (2013). Impact of lean practices on operations performance and business performance: some evidence from Indonesian manufacturing companies. Journal of Manufacturing Technology Management, 24(7), 1019-1050. doi: 10.1108/JMTM-03-2012-0027
Nawanir, G., Lim, K. T., & Othman, S. N. (2015). Measurement instrument for lean manufacturing. International Journal of Applied Science and Technology, 5(4), 102-111.
Nawanir, G., Lim, K. T., & Othman, S. N. (In Press). Lean manufacturing practices in Indonesian manufacturing firms: Are there business performance effects? International Journal of Lean Six Sigma, 7(1).
Nawanir, G., Othman, S. N., & Lim, K. T. (2010). The impact of lean manufacturing practices on operations performance: A study on Indonesian manufacturing companies. Journal of Technology and Operations Management, 5(2), 39-51.
Ohno, T. (1988). The Toyota production system: Beyond large-scale production. Portland, OR: Productivity Press.
Papadopoulou, T. C., & Özbayrak, M. (2005). Leanness: experiences from the journey to date. General review, 16(7), 784-807. doi: 10.1108/17410380510626196
Pettersen, J. (2009). Defining lean production: some conceptual and practical issues. The TQM Journal, 21(2), 127-142. doi: 10.1108/17542730910938137
Podsakoff, P. M., MacKenzie, S. B., Lee, J.-Y., & Podsakoff, N. P. (2003). Common method biases in behavioral research: A critical review of the literature and recommended remedies. Journal of Applied Psychology, 88(5), 879–903. doi: 10.1037/0021-9010.88.5.879
Ramarapu, N. K., Mehra, S., & Frolick, M. N. (1995). A comparative analysis and review of JIT “implementation†research. International Journal of Operations & Production Management, 15(1), 38-49. doi: 10.1108/01443579510077188
Russell, R. S., & Taylor, B. W. (2011). Operations management, creating value a long the supply chain (7th ed.). New Jersey: John Willey & Sons, Inc.
Sakakibara, S., Flynn, B. B., & Schroeder, R. G. (1993). A framework and measurement instrument for just-in-time manufacturing. Production and Operations Management, 2(3), 177-194. doi: 10.1111/j.1937-5956.1993.tb00097.x
Sakakibara, S., Flynn, B. B., Schroeder, R. G., & Morris, W. T. (1997). The impact of just-in-time manufacturing and its infrastructure on manufacturing performance. Management Science, 43(9), 1246-1257.
Sekaran, U., & Bougie, R. (2009). Research methods for business: A skill building approach (5th ed.). West Sussex, United Kingdom: John Willey & Sons Ltd.
Shah, R., & Ward, P. T. (2003). Lean manufacturing: Context, practice bundles, and performance. Journal of Operations Management, 21, 129-149. doi: 10.1016/S0272-6963(02)00108-0
Shah, R., & Ward, P. T. (2007). Defining and developing measures of lean production. Journal of Operations Management, 25, 785-805. doi: 10.1016/j.jom.2007.01.019
Singh, G., & Ahuja, I. S. (2014). An evaluation of just in time (JIT) implementation on manufacturing performance in Indian industry. Journal of Asia Business Studies, 8(3), 278-294. doi: 10.1108/jabs-09-2013-0051
Slack, N., Chambers, S., & Johnston, R. (2010). Operations management (6th ed.). England: Pearson Education Ltd.
Stevenson, W. J. (2012). Operations management (11th ed.). New York: McGraw-Hill/Irwin.
Thanki, S. J., & Thakkar, J. (2014). Status of lean manufacturing practices in Indian industries and government initiatives: A pilot study. Journal of Manufacturing Technology Management, 25(1), 655-675. doi: 10.1108/JMTM-05-2012-0057
West, S. G., Finch, J. F., & Curran, P. J. (1995). Structural equation models with nonnormal variables: Problems and remedies. In R. H. Hoyle (Ed.), Structural equation modeling: Concepts, issues, and applications (pp. 56-75). Thousand Oaks, CA: Sage Publications, Inc.
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04-06-2020
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Nawanir, G., Kong Teong, L., & Othman, S. N. (2020). VALIDATION OF LEAN MANUFACTURING MEASUREMENT INSTRUMENT. Journal of Technology and Operations Management, 10(2), 25–36. https://doi.org/10.32890/jtom2015.10.2.2
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