Purpose The purpose of this study is to present factors associated with process barriers in implementing lean manufacturing within the small- and medium-sized enterprises (SMEs). Design/methodology/approach This study was conducted to identify the process barriers in implementing lean manufacturing in SMEs. Moreover, by a thorough and detailed analysis, process barriers of high rejection rate, employee absenteeism and frequent breakdown with 29 associated variables were identified as the most critical process barriers and were used to develop the questionnaire. Structural equation modeling was used to build the measurement model by drawing on samples of 128 SMEs in Kerala, a state in India. Later, the model was validated using statistical estimates. Data analysis helps to determine whether to accept or reject the hypothesis on the basis of the measurement model. Findings Several process barriers that prevent the successful implementation of lean manufacturing within SMEs are identified. These are lack of a training program, lack of periodical maintenance, low-quality standard materials from suppliers, bad vendor inspection, wear and tear of machines, communication gap between supervisors and workers, non-maintenance of a good employee–employer relationship, boredom on the job, overrunning machines beyond the capability, carelessness in work, not replacing worn damage parts periodically, ignoring warning signals of the machine classified as the most critical process barrier among the high rejection rate, employee absenteeism, frequent breakdown factors. Research limitations/implications First, the sample size of the study was relatively small (128). Second, data collection was restricted to one geographical area in India, i.e. Kerala, a state in India, giving rise to operational constraints. Third, the study was cross-sectional; a longitudinal study must be performed to reinforce the findings. Practical implications The present study has explored an unfocused area of lean implementation in SMEs. The results are expected to help researchers, academics and professionals in the domain of lean manufacturing. Social implications Governments of many countries around the world are helping and encouraging the implementation and understanding of the lean manufacturing system by providing financial assistance for training professionals and establishing professional associations. However, many industries have not been successful in lean implementation. This research aims to develop a strategy to tackle process barriers for successful lean implementation. Originality/value Very little research has been carried out in exploring process barriers in implementing lean manufacturing in SMEs. This paper will provide value to academics, researchers and practitioners of lean by providing insight into significant process barriers for lean implementation, especially in Indian industries.

中文翻译：

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过程障碍的识别和建模

目的 本研究的目的是介绍与在中小型企业 (SME) 内实施精益制造的过程障碍相关的因素。设计/方法/途径 本研究旨在确定中小企业实施精益制造的过程障碍。此外，通过彻底和详细的分析，高拒绝率、员工缺勤和频繁故障以及 29 个相关变量的过程障碍被确定为最关键的过程障碍，并用于制定调查问卷。通过抽取印度喀拉拉邦 128 家中小企业的样本，使用结构方程模型建立测量模型。后来，该模型使用统计估计进行了验证。数据分析有助于根据测量模型确定是接受还是拒绝假设。结果 确定了阻碍中小企业成功实施精益制造的几个过程障碍。这些是缺乏培训计划、缺乏定期维护、供应商提供的低质量标准材料、供应商检查不良、机器磨损、主管与工人之间的沟通差距、未维护良好的员工-雇主关系、无聊在工作中，机器超负荷运转，工作粗心大意，不定期更换磨损的损坏零件，忽视机器的警告信号，被列为高废品率、员工缺勤、频繁故障因素中最关键的过程障碍。研究限制/影响首先，该研究的样本量相对较小（128）。其次，数据收集仅限于印度的一个地理区域，即印度的一个邦喀拉拉邦，从而导致操作上的限制。第三，这项研究是横断面的；必须进行纵向研究以加强研究结果。实际意义 本研究探讨了中小企业精益实施的一个非重点领域。预计结果将对精益制造领域的研究人员、学者和专业人士有所帮助。社会影响 世界上许多国家的政府正在通过为培训专业人员和建立专业协会提供财政援助来帮助和鼓励精益制造系统的实施和理解。然而，许多行业在精益实施方面并未取得成功。这项研究旨在制定一项战略，以解决成功实施精益的过程障碍。原创性/价值 很少有研究探讨中小企业实施精益制造的过程障碍。本文将通过深入了解精益实施的重大流程障碍，尤其是在印度工业中，为精益的学者、研究人员和实践者提供价值。