LEAN MANUFACTURING PRACTICES AND SUPPLY CHAIN PERFORMANCE OF SUGAR MANUFACTURING FIRMS IN WESTERN KENYA

Authors

  • Bob Ochieng

DOI:

https://doi.org/10.47672/ajscm.719

Keywords:

Just in Time Production, Total Quality Control, Supply Chain Performance, Sugar Manufacturing Firms, Kenya

Abstract

Introduction: Western Kenya is the largest producer of sugar in Kenya, supporting about 170,000 smallholder farming households and contributing about 80 percent of the total sugar produced in Kenya. This contribution is however threatened given that the sugar firms in that region are producing sub optimally with obsolete technology. Comparing to related sector, other firms in Kenya such as the tea manufacturing firms have implemented energy efficiency practices so as to manage energy wastage and reduce production costs. Were they to employ effective production methods, they could increase their production significantly. While that is the case, scholars have suggested that adoption of lean manufacturing practices is a panacea to quality addition and waste minimization. Perhaps what these firms need are lean practices.

Purpose: This study interrogated the extent to which the firms have adopted lean manufacturing practices, just-in-time and total quality control and if they have, its effect on supply chain performance.

Methodology: The study targeted and conducted a census on the 11 sugar manufacturing firms in the Western Kenya belt where the procurement managers, line managers, finance managers, production managers, production engineers, quality assurance officers and operations managers of each of the 11 firms (total 87) were targeted. The study employed a descriptive research design to collect quantitative data. Quantitative primary data was collected through questionnaires and analyzed using statistical package for social sciences.

 Findings: The findings of the study indicated that the just in time productionand total quality control are positively and significantly associated with supply chain performance of the sugar manufacturing firms.

Unique Contribution to Practice and Policy: The study recommended adoption of just in time production practices such as availing labor on demand in order to manage labor costs, availing resources on demand in order to manage wastage, production on demand in order to manage inventory costs, ordering raw materials from the suppliers only when there is demand for production from customers, having a simplified production design to ensure timely production and having multiple skilled workers to ensure faster production. In addition, in order for the sugar manufacturing firms to increase supply chain performance, there is need to adopt total quality control practices such as having manageable defect prevention costs related to quality planning, putting in place manageable defect prevention costs related to investment in quality related information systems, having manageable appraisal costs related to test and inspection of purchased materials, having manageable appraisal costs related to quality audits, having controllable internal failure costs related to reworks and having manageable internal failure costs related to scrap.

Downloads

Download data is not yet available.

Author Biography

Bob Ochieng

Lecturer of Supply Chain Management

School of Business and Human Resource Development

Rongo University, Kenya

 

References

Bautista, J., & Fortuny-Santos, J. (2016). Improving "Just-In-Time, Just-In-Sequence" Delivery In First-Tier Suppliers. Brazilian Journal Of Operations & Production Management, 13 (3), 286.

Bhasin, S & Burcher, P., (2006). Lean viewed as a philosophy. Journal of Manufacturing Technology Management 17 (5), 57-72.

Dang, G., &Pheng, L. S. (2015). Research methodology. In Infrastructure Investments in Developing Economies (135-155). Springer, Singapore.

Fatuma, A. (2015). Quality management practices and supply chain performance of large scale manufacturing firms in Kenya. Unpublished Masters Project, University of Nairobi

Kenya National Assembly [KNA] (2015) Parliamentary Report of the Departmental Committee on Agriculture, Livestock and Co-Operatives on the Crisis Facing the sugar industry in Kenya. Kenya National Assembly, Eleventh Parliament (3rd Session-2015), Nairobi.

Kenya National Bureau of Statistics [KNBS] (2019) Economic Survey 2019. Republic of Kenya.

Mangeni, W. (2018). Other People's Money: External Debt, Disequilibrium Exchange Rate and Economic Growth, A Kenyan Case (1963-2015). Journal of International Business, Innovation and Strategic Management, 2(2), 191-223.

Mangeni, W., & Mike, O. (2018). The Weekend Effect: An Exploitable Anomaly on the Average returns of Nairobi Securities Exchange. Journal of International Business, Innovation and Strategic Management, 2(2), 37-51.

Masindet, E. & Ogollah, K. (2014). Influence of Total Quality Management Practices onSupply Chain Performance of Cement Manufacturing Firms in Kenya.European Journalof BusinessManagement,1 (11), 181-197.

Mati, B. M., & Thomas, M. K. (2019). Overview of sugar industry in Kenya and prospects for production at the coast. Agricultural Sciences, 10(11), 1477-1485.

Moroz, E. (2018). Computer aided manufacturing processes using Lean Management and Lean Manufacturing methods. Mechanik, (7), 535-537.

Muhammad, B. H. (2014). Supply chain management: Practices, performance and its impact on business performance. Unpublished M. Sc Thesis of the University of Utara,.

Mutua, M., Ngugi, P., & Odhiambo, R. (2018). Influence of Lean Production Practices on Performance of Large Manufacturing Firms in Kenya. Journal of International Business, Innovation and Strategic Management, 1(8), 58-76.

Nyaga, G. N., Whipple, J. M. & Lynch, D. F. (2010). Examining Supply Chain Relationships: Do Buyer And Supplier Perspectives on Collaborative Relationships Differ? Journal of Operations Management, 28 (2), 101-114.

Okello, J. O., & Were, S. (2014). Influence of supply chain management practices on performance of the Nairobi Securities Exchange's listed, food manufacturing companies in Nairobi. International Journal of Social Sciences and Entrepreneurship, 1(11), 107-128

Paneru, N. (2011). Implementation of Lean Manufacturing Tools in Garment Manufacturing Process Focusing Sewing Section of Men's Shirt, Doctoral dissertation, Oulu University of Applied Sciences.

Ralescu. D. (2009). Management application of system theory. Proceedings of the IEEE, 68 (7), 943-944

Rand, G. (2011). Just-in-Time Manufacturing in Perspective. Journal of the Operational Research Society, 44 (7), 734-735.

Reichhart, A. & Holweg, M. (2007). Creating the customer-responsive supply chain: a reconciliation of concepts. International Journal of Operations and Production Management, 27(11),1144-1172.

Richbell, S., & Ratsiatou, I. (2009). Establishing a shared vision under total quality management: Theory and practice. Total Quality Management, 10(4-5), 684-689.

Rucha, K. M. (2018). Lean Practices and Operational Performance of Third Party Port-Centric Logistics Firms in Kenya, Doctoral dissertation, JKUAT COHRED.

Sayid Mia, M. (2017). Implementation of Lean Manufacturing Tools in Footwear Industry of Bangladesh. Aspects in Mining & Mineral Science, 1(1), 90-134

Silverman, D. (Ed.). (2016). Qualitative research. Sage.

Stensaasen, S. (1995). The application of Deming's theory of total quality management to achieve continuous improvements in education. Total Quality Management, 6(5), 579-592.

Sumo, J. (2015). Lean practices and supply chain performance among automotive assembling firms in Kenya (Masters). University of Nairobi, Unpublished Masters Project

Tripathi, N., & Tiwari, S. Lean Manufacturing Practices and Firms Performance Measurement-A Review Paper. Https://Www.Researchgate.Net/Publication/308960626.

Tsuchiya, S. (2010). Quality maintenance: Zero defects through equipment management. Productivity Press, Cambridge, MA

Vore, R. (2002). Competitive manufacturing through total productive maintenance. Semiconductor Manufacturing Science Symposium. ISMSS 1992, IEEE/SEMI International, June 15-16, pp. 85-9.

Wawire, N.W., Jamoza, J.E., Shiundu R., Kipruto K.B. and Chepkwony, P. (2006) Identification and Ranking of Zonal Sugarcane Production Constraints in Kenya. KESREF Technical Bulletin, No. 1, 78-102.

Downloads

Published

2021-05-21

How to Cite

Ochieng, B. . (2021). LEAN MANUFACTURING PRACTICES AND SUPPLY CHAIN PERFORMANCE OF SUGAR MANUFACTURING FIRMS IN WESTERN KENYA. American Journal of Supply Chain Management, 6(1), 27–43. https://doi.org/10.47672/ajscm.719

Issue

Section

Articles