1. Topics for research:
Evaluating the Lean Manufacturing System in the Small and Medium Enterprise
Industry in Bangladesh
Project Keywords: Lean manufacturing system, Lead time, SME (small & medium
enterprise), improved quality, Elimination of waste.
2. Background of project research
The Lean Manufacturing system has consistently outperformed all other manufacturing
methods in recent years, and many businesses today are using it (Wanitwattanakosol &
Sopadang, 2012). Lean Manufacturing aims to develop a well-functioning system that
consistently produces things of good quality that fulfil customer demand and generates no
waste (Nordin, Md Deros, & Abd Wahab, 2010). Consequently, the Lean Manufacturing
system helps businesses remain competitive by enhancing their capacity to produce higherquality products and reducing delivery time (Singh, Garg, & Sharma, 2009). Small and
medium-sized enterprises (SMEs) may effectively apply Lean management even with
minimal resources (Lee, 1997). Lean would aid businesses in optimising their use of
resources to increase output and better satisfy customers (Golhar, Stamm, & Smith, 1990).
SMEs should apply the Manufacturing system by using essential approaches that do not need
significant financial investment, such as Kaizen, 5S, and Mieruka (Lee, 1997). Over 90%
(Rahman, 2015) of Bangladesh's businesses are in this category, although there are several
causes for their slow expansion. In addition, the COVID-19 pandemic has significantly
impacted the operations of SMEs (Khan & Haider, 2022). That's why it's essential to
establish innovative strategies for managing SMEs that increase their production and
competitiveness. Operational activities under Lean manufacturing are popular as it brings
effective modifications in overall equipment efficiency, reduce defect rate and inventory,
improve the flexibility of work, decrease lead time and improves labour productivity and thus
ensures quality full and increased production (Ahmed & Sobuz, 2019). Lean aims at
eliminating waste of any type. Like a waste of human efforts, waste of inventory and waste of
time (Shrimali & Soni, 2017). Again workers’ involvement as a part of Lean manufacturing
implementation has a direct impact on the morale of the personnel and for this reason, it
improves the organizational way of life and improves the overall performance of the industry
(Kumar & Kumar, 2014). There are a few challenges that make it challenging for small and
medium-sized enterprises (SMEs) in Bangladesh to adopt lean manufacturing practises. Like
lack of proper understanding of the lean manufacturing system and its implementation knowhow, small size of the enterprise and lack of resources, worker’s attitude, and reluctance of
SME management and organizational culture (Shrimali & Soni, 2017). If the lean
manufacturing system is not implemented in the SMEs, then it will be very perplexing to
improve quality by minimizing defects, waste reduction, and improving supplier-customer
relationships by reducing lead time. And it is also very difficult to enhance finishing
receptivity through motion exclusion if a lean manufacturing system is not implemented
(Habib, Rizvan, & Ahmed, 2023). The SMEs where the lean manufacturing system isn’t
implemented, aren’t capable to achieve the maximum output by using the minimum input
such as less time, less space, less human exertion, less material, less machinery and minimum
cost (AlManei, Salonitis, & Xu, 2017).
3. Literature Review
Production with little waste is the goal of lean manufacturing, which is why an integrated set
of disciplines and the use of operations management tools lead to greater efficiency and
productivity (Kunyoria & Aila, 2022). A major focus of LMPs is to help workers work
toward a state of continuous improvement by identifying and removing any sources of waste
(Bai, Satir, & Sarkis, 2019). Lean manufacturing eliminates inefficiencies, enhances
productivity, adds to high quality standards, and cuts down on lead times, all of which results
in a decrease in overall production costs (Panwar, Nepal, Jain, & Rathore, 2015). Lean
manufacturing is a method for reducing non-value-added operations, such as the constant
improvement and uninterrupted delivery of products to customers. That which does not
contribute to the product's value is considered waste. It is something that the customer isn't
always ready to spend money on (Sharma, 2014). A lean manufacturing system is a complete
set of values that includes tactics to discover and get rid of waste as well as techniques to add
value to goods and processes (Upadhye, Deshmukh, & Garg, 2010). The ultimate purpose of
a lean enterprise is to create a smooth and highly satisfactory enterprise that is capable to
produce finished goods satisfying the customer's demand with high-quality & suitable to the
customer and with no waste (Kumar & Kumar, 2014). Lean management is a new approach
to business that prioritises happy customers and increased value creation by eliminating
unnecessary processes (Minh, 2020). Lean manufacturing systems are necessary for
maintaining efficient operations in today's dynamic and unpredictable business landscape
(Nawanir, Fernando, & Teong, 2018). In addition, organizations are placing a priority on lean
manufacturing processes as a means to improve production output (Wickramasinghe &
Wickramasinghe, 2017). Hines, Holweg, and Rich (2004) concluded that implementing lean
production at the operational level is essential for gaining a full understanding of lean and for
using the appropriate tools and methods to provide value to customers. The benefits of using
the Lean manufacturing system are well acknowledged. Several studies have shown the
limitations of the LM. There is still a role for batch production in terms of both the work's
design and the manufacturing method (Cooney, 2002). According to the results of Bhasin and
Burcher (2006), an adaptation of a lean manufacturing system is still experiencing obstacles,
and they identified the root factors for the poor success rates of the lean manufacturing
system.
4. Justification/Rationale of the study

The study will help the Lean manufacturing system to create an atmosphere that is
friendly to cut down on waste in both operations and company culture.

It will help to use the lean manufacturing system as a framework for strategic
planning and the development of important phases via methodical working
instructions (Melton, 2005).

Assist in increasing adaptability and capturing a big portion of the market.

Furthermore, this research will aid in employing the lean manufacturing system as a
methodology with a set of tools for maximizing efficiency and quality at low cost
(Jayanth, Prathap, Sivaraman, Yogesh, & Madhu, 2020).
5. Objectives of the study:
a. To enlighten the importance of practicing lean manufacturing system in the SME
industry of Bangladesh.
b. To understand and gather distinct standpoints of related parties about using lean
manufacturing system in SME industry of Bangladesh.
6. Research methodology
In this experimental research a conceptual model has been tried to develop to encourage and
ensure the increased practice of lean manufacturing system in the SME industry of
Bangladesh. To find out existing gap, the existing literatures including laws and policies have
been reviewed. A deductive approach has been used in this study. Here according to the
objective an initial overview of methodology has been shown below:
Table 1: An overview of the methodology
Sly Objectives
Sources
Data collection Data Analysis
Tools
of data
method
to
be
used
1
To
enlighten
the Secondary Journals, articles, Qualitative
importance
of
newspaper,
practicing
lean
databases,
NVivo*
(Content analysis)
laws
manufacturing system
and regulations,
in the SME industry
etc.
of Bangladesh.
2
To
understand
gather
and Primary
(Key Qualitative
and NVivo
Informant
Quantitative (SPSS and
standpoints of related
Interviews),
tools,
parties
about
using
FGDs
(Focus test, factor analysis, PLS**
lean
manufacturing
Group
regression analysis,
system
distinct
KIIs
in
SME
industry
of
Discussions) and cross
Survey.
Bangladesh.
Reliability smart
tabulation
analysis and group
t- test)
*Qualitative Data Analysis software, ** Quantitative Data Analysis Software
Sampling frame: The individuals and groups involved in the industry are the target
population for this research. This includes businesspeople, government officials,
manufacturers, and others. Journalists, economists, bankers, and government officials
involved in industrial regulation are also included.
Sampling unit: This study will be based on data collected through FGDs, KIIs, and a survey.
The sample unit is listed below following the study stages.
Table 2: Sampling unit
Stages/objective
Data
Sampling unit
collection
Sampling
method
method
Second
FGD
There will be one FGD with [number] Purposive
participants, and they will all be important
participants in the sector such as industry
practitioners, policymakers, industrialists,
industrial
journalists,
economists,
environmentalists,
bankers,
and
industrial
regulatory parties.
Second
KIIs
All [number] will be the most significant Purposive
stakeholder in the industry such as industry
practitioners, policymakers, industrialists,
industrial
journalist,
economists,
environmentalists,
bankers,
and
industrial
[200*],
are
regulatory parties.
Second
Survey
Respondents
number
all Purposive
experienced SME experts.
* Population identification is required for sample determination. This study will focus on two
main factors to determine the sample size: (i) Managerial employees and (ii) at least two
years of experience in the selected industry. SME Foundation reports that there were 7818565
number of SME in Bangladesh in the year 2013 (SMEF, 2013). For this study, the population
is estimated as 7818565. For the sample size calculation, we may use Yamane's formula
(Yamane, 1967):
𝑛=
𝑁
1 − 𝑁(𝑒)2
Where N is the population size and e is the acceptable sampling error. Using this method to
calculate sample size, the total sample size is determined to be [400]. However, contrasting
viewpoints exist; for instance, Hoe (2008) suggested a sample size of 200 as enough for
statistical analysis. Jackson (2001) also recommended sample size between 200 to 400 can be
employed for multivariate data analysis. Therefore, taking into account time and financial
constraints, this study would endeavour to collect data from around [200] participants to
disclose primary responses.
Instruments:
A systematic questionnaire for use in FGDs and KIIs will be developed. The KIIs will be
conducted in groups, whereas the FGDs will be conducted individually. A formal
questionnaire will be issued in order to perform a survey properly. All surveys will be
developed with the highest regard for reliability and validity.
Data Analysis:
This study will employ both qualitative and quantitative methodologies. Multiple methods of
qualitative analysis, including content analysis, analytic comparison, narrative analysis, and
conversation analysis, will make the use of QDA tool. Using SPSS techniques such as the
reliability test, factor analysis, regression analysis, cross-tabulation, and group t-test,
quantitative analysis will be undertaken.
7. Scope of the Study:


This research will concentrate solely on the national 3R strategy for waste
management, as it will assist policymakers in drafting rules in this area. To attain
these objectives, however, the lean manufacturing system requires an independent
study due to its expansive scope and diverse functional and strategic capacities.
While the lean manufacturing approach merits exploration across all industries, this
study focuses on small and medium-sized businesses (SMEs) in Bangladesh.
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