Relationship between lean manufacturing tools and their sustainable economic benefits.

Traditionally, the isolated relationship of total preventive maintenance (TPM), quick setup (QS), overall equipment effectiveness (OEE), and one-piece flow (OPF) with economic sustainability (ESU) has been investigated; however, these lean manufacturing (LM) tools are implemented together into production systems, and traditional research does not report their relationships and interactions. To contribute to this gap, this paper integrates all those variables in a structural equation model (SEM), which are related by seven hypotheses that are validated using the partial least squares (PLS) technique using information from 176 responses to a questionnaire applied to the Mexican maquiladora industry. Additionally, a sensitivity analysis has been carried out to determine the probability of occurrence at high and low implementation levels for all variables when they occur in isolation, jointly and conditionally. Findings indicate that TPM is a precursor of QS and OEE, while QS is a precursor of OEE and OPF, OEE is a precursor of OPF and ESU, but also OPF is a precursor of ESU. The sensitivity analysis indicates that low levels of TPM are a risk for reaching adequate levels of OEE and QC, while low levels in OEE and OPF are a risk for reaching adequate ESU levels. Supplementary Information: The online version contains supplementary material available at 10.1007/s00170-022-10208-0.

Effect of lean manufacturing tools on sustainability: the case of Mexican maquiladoras.

The Mexican maquiladora industry is applying Lean Manufacturing Tools (LMT) in its production lines; however, few studies have investigated its relationship with sustainability (social, economic, and environmental). This paper presents a second-order structural equation model (SEM) relating 8 LMT integrated into three independent latent variables: continuous improvement (Kaizen and Gemba), supporting tools (Andon, visual management, and Poka-yoke), and machinery and equipment (total productive maintenance, overall equipment effectiveness, and Jidoka) that are related to social, economic, and environmental sustainability as dependent variables. The model is validated with information obtained from 249 companies using partial least squares. Findings show that the application of LMT in the Mexican maquiladora industry avoids the generation of waste and reprocessing. Likewise, the improvement of production processes reduces the waste emitted into the environment and reduces energy consumption. Also, when companies have environmental programs, the work environment is safe, and labor relations are improved, increasing morale and the commitment to work for the company, gaining economic and ecological benefits.