Implementation and Impact of Lean Manufacturing: A Critical Review and Framework for Adoption

Year : 2025 | Volume : 03 | Issue : 02 | Page : 1 7
    By

    Darshan H Bhalodia,

  • Rishabh D Makwana,

  • Parth M Lakum,

  • Rohit R Raval,

  • Heena M. Patel,

  1. Assistant Professor, Department of Mechanical Engineering, Atmiya University, Rajkot, Gujarat, India
  2. Assistant Professor, Department of Mechanical Engineering, Atmiya University, Rajkot, Guajrat, India
  3. Assistant Professor, Department of Mechanical Engineering, Atmiya University, Rajkot, Gujarat, India
  4. Assistant Professor, Department of Mechanical Engineering, Atmiya University, Rajkot, Gujarat, India
  5. Assistant Professor, Department of Mechanical Engineering, Atmiya University, Rajkot, Gujarat, India

Abstract

Lean manufacturing has become a vital approach for organizations seeking to enhance efficiency, reduce waste, and strengthen competitiveness in dynamic industrial environments. Although lean principles are well established, industries continue to experience inconsistencies in implementation outcomes due to differences in organizational readiness, employee involvement, and managerial commitment. This study critically reviews existing research on lean manufacturing to examine its practical impact, the factors influencing its success, and the challenges that hinder sustainable adoption. Through an analysis of global case studies and scholarly contributions, the paper evaluates the effectiveness of core lean tools—such as 5S, Kaizen, Value Stream Mapping, Just-in-Time production, and Total Productive Maintenance—in improving process flow, reducing variability, and fostering continuous improvement The review highlights that while lean practices consistently improve productivity, quality, and cost performance, their benefits often remain limited when implementation is fragmented or lacks cultural integration. Common barriers include inadequate training, resistance to change, insufficient monitoring systems, and limited leadership engagement. To address these constraints, the study proposes a structured Lean Adoption Framework comprising seven stages: organizational diagnosis, strategic alignment, process mapping and waste identification, pilot testing, capability development, full-scale integration, and ongoing evaluation supported by feedback loops. This framework provides a practical roadmap to guide industries in adopting lean systematically and sustainably The findings emphasize that lean manufacturing yields long-term operational advantages when treated as a continuous improvement philosophy rather than a short-term cost-cutting initiative. The proposed framework serves as a reference for researchers and practitioners aiming to strengthen lean implementation strategies and achieve sustained operational excellence.

Keywords: Lean manufacturing, waste reduction, continuous improvement, SMEs, lean implementation, sustainable manufacturing

[This article belongs to International Journal of Industrial and Product Design Engineering ]

How to cite this article:
Darshan H Bhalodia, Rishabh D Makwana, Parth M Lakum, Rohit R Raval, Heena M. Patel. Implementation and Impact of Lean Manufacturing: A Critical Review and Framework for Adoption. International Journal of Industrial and Product Design Engineering. 2025; 03(02):1-7.
How to cite this URL:
Darshan H Bhalodia, Rishabh D Makwana, Parth M Lakum, Rohit R Raval, Heena M. Patel. Implementation and Impact of Lean Manufacturing: A Critical Review and Framework for Adoption. International Journal of Industrial and Product Design Engineering. 2025; 03(02):1-7. Available from: https://journals.stmjournals.com/ijipde/article=2025/view=235256


References

  1. Hernández Centeno, F., & Sifuentes Huayanay, W. (2022). Lean Manufacturing: Literature review and implementation analysis. Journal of Scientific and Technological Research Industrial.
  2. Patel, J. S., & Patange, G. S. (2017). A review on benefits of implementing Lean Manufacturing. International Journal of Scientific Research in Science and Technology (IJSRST).
  3. Abidin, M. H. Z., Leman, Z., Yusof, M., & Khalili, A. (2022). Lean impact on manufacturing productivity: A case study of Industrialized Building System (IBS) manufacturing factory. Jurnal Teknologi.
  4. Suroso, E., & Santosa, A. D. (2022). Effects of Lean Manufacturing Practices on Operational Performance. Journal of Research in Social Science and Humanities.
  5. Rahardjo, B., Wang, F.-K., Yeh, R.-H., & Chen, Y.-P. (2023). Lean Manufacturing in Industry 4.0: A Smart and Sustainable Manufacturing System. Machines, 11(1), 72.
  6. Abualfaraa, W., Salonitis, K., Al‑Ashaab, A., & Ala’raj, M. (2020). Lean-Green Manufacturing Practices and Their Link with Sustainability: A Critical Review. Sustainability, 12(3), 981. https://doi.org/10.3390/su12030981
  7. Jasti NV, Kodali R. Lean manufacturing frameworks: review and a proposed framework. European Journal of Industrial Engineering. 2016;10(5):547-73.
  8. Raval SJ, Kant R. Study on Lean Six Sigma frameworks: a critical literature review. International Journal of Lean Six Sigma. 2017 Aug 7;8(3):275-334.
  9. Bhamu J, Sangwan KS. A framework for lean manufacturing implementation. International Journal of Services and Operations Management. 2016;25(3):313-33.
  10. Panwar A, Nepal BP, Jain R, Rathore AP. On the adoption of lean manufacturing principles in process industries. Production Planning & Control. 2015 May 19;26(7):564-87.
Regular Issue Subscription Review Article
Volume 03
Issue 02
Received 03/12/2025
Accepted 13/12/2025
Published 26/12/2025
Publication Time 23 Days
54

Login


My IP

PlumX Metrics