How Lean Tools Contribute to a Production System, Investigation in the Automotive Industry

Lean Manufacturing adoption is a gradual process, and the application status of Lean tools influences enterprise performance. Only well-prepared Lean initiatives bring real benefits. This study aims to identify the effective Lean tools required for eliminating waste and also verify the main factors that motivate companies to Lean applications. The study adopted a quantitative research method. Research data were collected through a questionnaire to the target population of medium and large companies in the automotive industry in Poland. The study confirmed that Lean tools are regularly implemented in automotives and the most popular tools are 5S and Visual Management. Statistically significant relationships were identified between specific Lean tools and waste reduction. The widest relationship with waste reduction is observed in VSM application, which is not frequently used by companies. This suggests that great benefits can be obtained when an organization employs the approach focusing on the whole stream of value in the company. The research reveals a challenge with physical stream and in cooperation in value chains in front of vast part of studied companies. The study provides also a basis for a practical guidance for business how to introduce Lean tools to eliminate particular types of waste.