The impact of Lean Manufacturing (LM) implementation on organizational performance is an ongoing discussion. The effect of implementing LM tools on operational performance across various industries in Zimbabwe, a country with an unstable real gross domestic product is evaluated. A structural model of LM that is aligned with the Toyota Production System (TPS) house was proposed. A structured survey questionnaire was used for the collection of data in identified companies. Of the 600 companies contacted, 214 useful responses were obtained implying a response rate of 35.6%. The structural and operational models were tested using the Statistical Package for Social Sciences and SmartPLS 3. The result indicated that operational performance was improved by implementing the selected LM tools.

The quality of products produced over the years has been the major concern for many industries. In brewing, the introduction of automated brewing systems has helped to reduce the variability of beer produced. The reasons for introducing the automated systems are to reduce energy usage and the batch processing time by increasing equipment utilization. The main aim of the paper is to design a control system that helps in monitoring and controlling the mashing process, temperature and monitor the water level that is put in the cookers during sorghum beer brewing. The research carried out showed that companies in Zimbabwe use dry bulb thermometers to measure the temperature of mash in the cooker. The companies also have no level measurement sensors that would measure the amount of water that would be poured into the cooker to primarily cool the mash. The design of the control circuit was done using sensors and controllers. For controlling the temperature a PID controller was used. The m...

The impact of Lean Manufacturing (LM) implementation on organizational performance is an ongoing discussion. The effect of implementing LM tools on operational performance across various industries in Zimbabwe, a country with an unstable real gross domestic product is evaluated. A structural model of LM that is aligned with the Toyota Production System (TPS) house was proposed. A structured survey questionnaire was used for the collection of data in identified companies. Of the 600 companies contacted, 214 useful responses were obtained implying a response rate of 35.6%. The structural and operational models were tested using the Statistical Package for Social Sciences and SmartPLS 3. The result indicated that operational performance was improved by implementing the selected LM tools.

Breweries in Zimbabwe use limited or no control systems at all. The aim of this study was to design a control system for monitoring and controlling mashing and cooling processes during production of a sorghum beer brewing. The design of the control circuit was done using sensors and controllers. For temperature control a PID controller was used. The system was able to raise the temperature of the mash to 50˚C for 50 minutes for hydrolysis of protein, β glucons and pentasons by proteolic enzymes. The temperature was then raised to 80˚C and maintained constant for 10 minutes for optimal activity of β-amylase. It was then raised to 95˚C for the optimal activity of α- amylase. Finally, the temperature was raised to 100˚C and was held constant for 60 minutes for enzyme inactivation. The control system designed in this study enhanced the process performance in the brewing of a sorghum beer.

The impact of Lean Manufacturing (LM) implementation on organizational performance is an ongoing discussion. The
effect of implementing LM tools on operational performance across various industries in Zimbabwe, a country with an
unstable real gross domestic product is evaluated. A structural model of LM that is aligned with the Toyota Production
System (TPS) house was proposed. A structured survey questionnaire was used for the collection of data in identified
companies. Of the 600 companies contacted, 214 useful responses were obtained implying a response rate of 35.6%. The
structural and operational models were tested using the Statistical Package for Social Sciences and SmartPLS 3. The result
indicated that operational performance was improved by implementing the selected LM tools.

The quality of products produced over the years has been the major concern for many industries. In brewing, the introduction of automated brewing systems has helped to reduce the variability of beer produced. The reasons for introducing the automated systems are to reduce energy usage and the batch processing time by increasing equipment utilization. The main aim of the paper is to design a control system that helps in monitoring and controlling the mashing process, temperature and monitor the water level that is put in the cookers during sorghum beer brewing. The research carried out showed that companies in Zimbabwe use dry bulb thermometers to measure the temperature of mash in the cooker. The companies also have no level measurement sensors that would measure the amount of water that would be poured into the cooker to primarily cool the mash. The design of the control circuit was done using sensors and controllers. For controlling the temperature a PID controller was used. The m...

In this study we explored the challenges involved in Lean Transformation and implementation in the manufacturing sector. Using survey data from 50 North American manufacturing organizations, we examined the challenges involved in implementing and sustaining Lean Manufacturing (LM) principles and practices in production processes. The fuzzy analytic hierarchy process (FAHP) and the fuzzy analytic network process (FANP) were used to rank the considerable challenges observed in these organizations. We concluded that the need for a change in organizational culture was the major barrier to Lean implementation. It is challenging to sustain Lean without a culture shift and a clear direction set by the organization’s leadership team. The originality of the paper relates to prioritizing the cultural aspects of organizations as a major barrier to LM implementation. Other challenges encountered during Lean implementation in the manufacturing industries were related to management support, techn...

Recent research asserts that Industry 4.0 technologies have positively impacted Lean Manufacturing and sustainable performance. Although the combined impact of Industry 4.0 and Lean Manufacturing on sustainable performance has been scientifically studied, no study has shown how Lean duration moderates the relationship between Industry 4.0 and Lean Manufacturing in US manufacturing firms. This research aims to close this gap by evaluating whether Lean duration moderates the association between Industry 4.0 and Lean Manufacturing, which in turn affects sustainability performance. The Structural Equation Modeling (SEM) method was used to formulate and examine proposed relationships. The study used data collected from 126 managers who worked in 65 different manufacturing organizations. The data demonstrated a moderating effect of Lean duration on the relationship between Industry 4.0 and Lean Manufacturing and a significant and direct effect of Lean Manufacturing on sustainable performa...

PurposeThis research aims to examine the complementary impact of Lean Manufacturing (LM) and Green Manufacturing (GM) on operational and environmental performance.Design/methodology/approachA survey was conducted in the Zimbabwean manufacturing industry. A total of 302 valid responses were obtained and analysed using partial least square structural equation modelling (PLS-SEM).FindingsBoth LM and GM impact environmental and operational performance; however, GM's effect on operational performance is indirect through environmental performance.Research limitations/implicationsThis study only focusses on the Zimbabwean manufacturing industry, and the results may not readily apply to other developing countries.Practical implicationsThe companies that have successfully implemented LM are able to implement GM more easily because of their complementary nature.Social implicationsThe integration of LM and GM reduces most forms of waste, causing an improved environmental and operational pe...