Lean Production Systems

Abstract

Toyota Production System approaches leanness by relying on an important subsystem called “respect-for-humanity”.  In contrast, anecdotal evidence suggests leanness in the Western world is often achieved as a result of “lean becomes mean”.  In this case study of a manufacturing plant in the United States, results from the structural equation model show suggestion autonomy, a self-reported measure, is lower than initially expected by the management team. Yet, other results illustrated the positive motivational effects of suggestion autonomy had on the worker’s well-being, which was manifested in the form of higher perceived employment security, lower effort-reward unfairness, higher job satisfaction, and higher overall satisfaction.  Results of second order factor from Structural Equation Modeling supported the extent theories that an integrated approach to organizational design is related to worker’s overall satisfaction. That is, the signaling effect of overall satisfaction by the workers can be used to gauge a firm before it moves in the direction of excessive leanness, decreased satisfaction and suboptimal performance.