Lean manufacturing applied in developing countries: a case study in metal industry
Abstract
This paper proposes a structured approach that integrates key lean manufacturing tools to improve the operational performance of companies in developing countries, particularly in Central Asia. A case study approach is applied to a manufacturing company in Uzbekistan. Four steps are carried out: selection of a case company; formation of a working team and definition of the current process mapping; selection of relevant key performance indicators and lean tools; implementing lean tools and assessing improvements. The total daily production rate of the case company increased by about 28% after lean application. Developing countries need special efforts to overcome the barriers related to the cultural background of companies and the mentality of their employees, in order to support the diffusion of lean manufacturing. This case study can stimulate academics to focus on further research on the application of lean tools in developing countries and the key contextual factors for its successful implementation.