Abstract
Efficiency and product quality are some of the key differentiators between competing entities in the manufacturing business environment. As such, improving efficiency and quality in the production processes are some of the main challenges in Small–Medium Enterprises (SMEs) in South Africa. Lean approach techniques are efficiency and process management practices adopted largely from Toyota Production Systems (TPS). There is limited literature on the usage of Lean 7S Methodology to improve SMEs process flow efficiency categorically. Most SMEs are established in response to a unique need in society. Most of the time this done quickly, with little attention to operational systems. Lean 7S Methodology which could be applied by any scope of an organisation is derived from the Japanese Lean 5s Methodology; Sort, set in order, Shine, Standardise and Sustain (or Self Discipline), extended by Safety as well as Spirit/Support representing the seven (7) steps in this Methodology. The purpose of this investigation was to examine the manufacturing process flow of the case company using the Lean approach as the primary investigation tool – specifically the Lean 7S Methodology, to identify critical areas for enhancement. This investigation will be conducted using a mixed method. Organisational photography and 7S Lean Audit were utilised to assess the process flow. Questionnaires were dispensed to a simple random sample of the case company with 120 people in the central Johannesburg region. For data analyses, Cronbach’s Alpha Measurement was utilised to authenticate the and reliability of the measuring instrument. Chi-square tests were utilised to establish whether there would be a positive association between the Lean approach, Lean 7S in particular and improved process flow efficiency to enhance organisational effectiveness. The outcomes of the investigation showed that the Lean approach, in particular, Lean 7S Methodology have a favourable effect on the organisational performance measures thus improving process flow efficiency. Consequently, it was established that Lean 7S Methodology contributes substantially towards process flow efficiency and organisational performance and in a manufacturing organisation. It is anticipated that this study’s findings will contribute to the ongoing efforts to enhance and advance process efficiencies in manufacturing SMEs and therefore enhance organisational performance.
M.Tech. (Operations Management)