The Efficacy of Lean Manufacturing on Organisational Performance. A Case Study of Zimbabwean Beverages Manufacturing Companies

Abstract

The impact of Lean Manufacturing (LM) on organisational performance is an ongoing discussion globally. Zimbabwean companies have implemented LM tools for operational performance across various industries. The Beverage industry has also been identified to be focusing on initiatives such as developing products that are less expensive, sell better and faster for it to remain competitive and reclaiming market shares, sales revenue and profitable in today's global market. The primary goal of this study was to determine the efficacy and viability of lean manufacturing processes at Zimbabwean Beverages production plants. The study used a qualitative research methodology, which yielded in-depth, detailed and rich data from human viewpoints and experiences resulting in a realistic understanding that was interpreted using the participants' social and cultural context. A total of thirty participants were purposeful selected based on their knowledge of the phenomenon under investigation. Physical face-to-face interviews, Ms team interviews, and focus groups responded to semi-structured interviews in data collection. Document analysis was used to collect data. The study found out that Zimbabwean Companies have not fully adopted lean manufacturing because of scepticism from management on the cost involved and the fear of losing jobs by the shop floor workers. The study however unearthed that manufacturing companies would benefit from lean manufacturing principles performance. Overwhelming evidence availed was that by implementing lean tools such as JIT methods, the organizations would be able to cut waste, reduce inventory holding costs and develop supplier relationships. TPM and VSM were found to have the potential to improve productivity and quality. The study recommends that suitable training programs should be designed to provide management with knowledge and skills to apply the positive traits to incorporate the lean concept into the organizations. and through buyin from shop floor workforce increase company performance.