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Lean Management
The Impact of Lean Implementation on Operational Performance: A
Study of Composite Manufacturing Companies in Malaysia

1.0

BACKGROUND INFORMATION

In 2012, the Asia-Pacific region accounted for 36 per cent of the worldwide market in value for composite production and 41 per cent in volume, according to
Frederique Mutel, president and chief executive officer of the JEC Group, which is the world‟s largest composite industry organization, representing, promoting and expanding the industry. From JEC group‟s annual survey the Asia-Pacific region has experienced strong growth rates in terms of composites production 6.9 per cent per annum, according to of the composites market since 2002. By 2015, the region is expected to account for 50 per cent of total composites production for all sectors, not just aerospace.
In Malaysia, Composites Technology Research Malaysia (CTRM), Asian
Composites Manufacturing (ACM) and SME Aerospace are winning composite work from the majors (Mutel, 2013). CTRM is a major supplier for composites for the Airbus
A320 family, supplying 20 per cent of the wing surface. In addition, it is active on
Boeing programs (737, 767, 777 and 787), Eurocopter helicopters (EC130), Bombardier
CSeries and the Mitsubishi Regional Jet. ACM, meanwhile, which is a Boeing-Hexcel company, produces advanced composite structures for the wings for Boeing aircraft and is active on the 737, 747, 767 and 777 programs. Spirit Aerospace, the world‟s largest supplier of commercial aircraft assemblies and components, has established its own subsidiary in Malaysia named SME Aerospace which manufactures composite subassemblies for Airbus single-aisle aircraft, plus some A350 XWB work and 777 wing works. Mutel (2013) also stated that, with the growing use of composites in aerospace production comes a challenge. The whole aerospace supply chain is under pressure to deliver composites structures and parts with a triple challenge; quality, lightness and



References: Abdul-Wahab, A., Mukhtar, M., & Sulaiman, R. (2013). A Conceptual Model of Lean Manufacturing Dimensions Engineering and Informatics (pp. 1292-1298). Procedia Technology. Agus, A., & Hajinoor, M. (2012). Lean production supply chain management as driver towards enhancing product quality and business performance Ali, A., Islam, M., & Lim, P. (2012). A study of sustainability of continuous improvement in the manufacturing industries in Malaysia Dora , M., Goubergen, D., Molnar , A., Gellynck, X., & Kumar, M. (2012). Application of lean practices in small and medium-sized food enterprises Fullerton, R., & Wempe, W. (2009). Lean manufacturing, non-financial performance measures, and financial performance Ghosh, M. (2012). Lean manufacturing performance in Indian manufacturing plants. Gunasekaran, A., Patel, C., & McGayghey, R. (2004). A framework for supply chain performance measurement Gupta, V., Acharya , P., & Patwardhan, M. (2013). A strategic and operational approach to assess the lean performance in radial tyre manufacturing in India Gurumurthy, A. a. (2011). Design of lean manufacturing systems using value stream mapping with simulation: a case study Habidin, N., & Yusof, S. (2013). Critical success factors of Lean Six Sigma for the Malaysian automotive industry Hon, K. (2003). Performance and Evaluation of of Manufacturing Systems. Liverpool: Department of Engineering University of Liverpool. Kelly , E. (2013, June 6). Asian Aviation. Retrieved April 1, 2014, from Asian Aviation: http://www.asianaviation.com/articles/407/Composite-competence Kuhlang, P. E. (2011). Methodical approach to increase productivity and reduce lead time in assembly and production-logistic processes Laosirihongthong, T., Rahman, S., & Sohal, A. (2010). Impact of lean strategy on operational performance - A study of Thai manufacturing companies MacDufile, J., & Helper, S. (1997). Creating lean suppliers: diffusing lean production through the supply chain Meiling, J., Backlund , F., & Johnsson, H. (2012). Managing for continuous improvement in off-site construction Nawanir, G., Lim , K., & Othman, S. (2013). Impact of lean practices on operations performance and business performance Management 24, 1019-1050. Rodolfo de Castro, Perez , C., Simons, D., & Gimenez, G. (2010). Development of lean supply chains - A case study of the Catalan pork sector Schonbergerm, R. (2007). Japanese production management: an evolution with mixed success Shah, R., & Ward, P. (2003). Lean manufacturing: context, practice bundles, and performance Shah, R., & Ward, P. (2007). Defining and developing measures of lean production. Singh, A., & Singh, H. (2013). Application of lean manufacturing using VSM in an autoparts manufacturing unit. Journal of Advance in Management Research, 72-84. Taj , S., & Morosan, C. (2010). Impact of lean operations on the Chinese manufacturing performance Womack, J., & Jones, T. (2003). Lean Thinking: Banish Waste and Create Wealth in Your Corporation Womack, J., Jones, T., & Ross, D. (1990). The Machine that Changed the World. New York: McMillan. Zarei, M., & Fakhrzad, M. (2011). Food supply chain leanness using a developed QFD model

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