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Abstract
Purpose – Scarcity of resources, ecological imbalance, global warming, rising energy prices and the ever-
changing need for variety have attracted the government and manufacturers for sustainable development of
the industries. The integrated sustainable-green-lean-six sigma-agile manufacturing system (ISGLSAMS)
provides a solid platform for meeting both the customers’ variety needs and business sustainability
requirements. Many organizations opted for ISGLSAMS, but still due to various barriers organizations are
not able to fully implement ISGLSAMS. The purpose of this paper is to identify the barriers to the
ISGLSAMS, so that a more sustainable industrial manufacturing system and industrial symbiosis can be
developed.
Design/methodology/approach – A literature review, from the Web of Science and Google Scholar
database, has been carried out to identify the various barriers to the implementation of ISGLSAMS in
the entire value chain. A total of 168 research papers have been reviewed for identifying the ISGLSAMS
barriers.
Findings – This paper elaborates the concept of the ISGLSAMS, its attributes and various barriers and
contributes to a better understanding and successful implementation of ISGLSAMS to meet business’
sustainability and market performance goals in the entire value chain. The paper also projects the future
research framework and directions for the ISGLSAMS, integrated sustainable-green-lean-six sigma-agile
(ISGLSA) product and ISGLSA supply and value chain.
Practical implications – The study contributes to a better understanding of ISGLSAMS’ barriers. The
government, stakeholders and policymakers may plan the policy, road map and strategies to overcome the
ISGLSAMS’ barriers. In-depth knowledge of subclauses of ISGLSAMS’ barriers will help the practitioners to
overcome the ISGLSAMS’ barriers strategically. By overcoming the ISGLSAMS barriers, a more sustainable
7 Rs based market focused manufacturing system can be designed. This will also increase the opportunities to
enhance the industrial ecology, industrial symbiosis and better recovery of the product, process and supply
chain residual value. This will reduce the waste to the ecosystem.
Originality/value – This work has been carried out in search of a more sustainable manufacturing system,
i.e. ISGLSAMS (which is 7 Rs based, i.e. 6 Rs of sustainability with 7th R, reconfiguration) to meet the
customer variety needs along with sustainability in the ever-changing customer market. This study adds
value to the practitioners to identify and prioritize the ISGLSAMS’ industry-specific barriers and design the
Benchmarking: An International
solution for the more sustainable development of (1) industries, (2) the industrial symbiosis system and (3) the Journal
ISGLSA product, process, system and supply value chain with minimum resource consumption and © Emerald Publishing Limited
environmental impact. The research also contributes to the (a) ISGLSAMS (b) ISGLSA supply chain (c) 1463-5771
DOI 10.1108/BIJ-10-2021-0585
BIJ reconfigurable, sustainable and modular products and (d) redesign, recovery and refurbishing of the product
to increase the product life cycle.
Keywords Integrated sustainable-green-lean-six sigma-agile manufacturing system (ISGLSAMS), Integrated
sustainable-green-lean-six sigma-agile (ISGLSA) manufacturing strategy, Sustainable products, Sustainable
supply chain, Social, environmental, market, ecological and financial performance, Industrial ecology and
industrial symbiosis
Paper type Literature review
1. Introduction
The scarcity of resources, ecological imbalance, global warming, rising energy prices and
ever-changing demand for variety have attracted the government and manufacturers for
sustainable development of the industries (Hariyani and Mishra, 2022a, b). Over the past
decades, various manufacturing strategies, viz., lean manufacturing (LM), green
manufacturing (GM), sustainable manufacturing (SM), six sigma process/technique and
agile manufacturing (AM) have evolved to meet the various needs of the stakeholders
and organization. Each of these manufacturing strategies is having its advantages (Hariyani
and Mishra, 2022b). Here is a brief overview of these manufacturing strategies:
Value = Quality + Services + Social Values – Cost – Lead time – Environmental foot print during life cycle
3. Research methodology
To answer the research question, a systematic literature review of the sustainable, green,
lean, six sigma, and AM barriers is carried out. The selection of papers to be included in the
literature review is done as per Moher et al., (2009) involving (a) identification of the papers,
Figure 2.
Timeline path of
innovation in
manufacturing
strategy and
stakeholders’ value
Barriers to the
2. Design for adoption of
environment
ISGLSAMS
Environmental effect
Life cycle factor
1. Design for Ecological balance and
functionality efficiency 3. Design for society
Service life/Durability Regional and Global
impact Operational safety
Functional effectiveness
Health and wellness
Ease of use
effect
Maintainability
Ethical responsibility
Upgradability
Social impact
Ergonomics
Reliability
4. Design for
8. Design for workers recycle/remanufacture
safety
Operational safety
Process Design in Disassembly
Recyclability
Health impact ISGLSAMS Disposability
Ethical responsibility Remanufacturability
Reusability
Figure 3.
Process design for the
ISGLSAMS
Note(s): Hariyani and Mishra, 2022a
(b) screening, (c) eligibility and (d) inclusion steps. As for the identification step, the Web of
Science and Google scholar database was included. The database was queried between Apr.
15th, 2020 and Aug. 25th, 2021. The search criteria include (1) the terms “Lean” AND
“Manufacturing” and “Barriers,” “Agile” and “Manufacturing” and “Barriers,” “Green” and
“Manufacturing” and “Barriers,” “Six Sigma” and “Manufacturing” and “Barriers,”
“Sustainable” and “Manufacturing” and “Barriers,” “Lean” and “Manufacturing” and
“Practices,” “Agile” and “Manufacturing” and “Practices,” “Green” and “Manufacturing”
and “Practices,” “Six Sigma” and “Manufacturing” and “Practices” and “Sustainable” and
“Manufacturing” and “Practices,” in the title. This limitation was necessary since browsing in
the full text returned a very large number of results. The period of publications was not
specified during the search. In the screening process papers other than the English language
and full content access denied papers were excluded. In the eligibility step, the full contents of
articles were analyzed with the following exclusion and inclusion criteria: (1) Papers in which
the terms “Sustainability” and “Barriers,” “Green” and “Barriers,” “Lean” and “Barriers,”
“Agile” and “Barriers” and “Six Sigma” and “Barriers” were not used in the sense of the
research question were excluded. (2) Papers with individual barriers and relevance were
BIJ
2. Design for
environment
Environmental effect
1. Design for Life cycle factor
functionality Ecological balance and
efficiency 3. Design for society
Service life/Durability Regional and Global
Functional impact Operational safety
effectiveness Health and wellness
Ease of use effect
Maintainability Ethical responsibility
Upgradability Social impact
Ergonomics
Reliability
8. Design for
4. Design for
Manufacturing
recycle/remanufacture
Manufacturing
Methods Product Design in Disassembly
Recyclability
Packaging
Assembly
ISGLSAMS Disposability
Remanufacturability
Storage
Reusability
Transportation
Figure 4.
Product design for the
ISGLSAMS
Note(s): Hariyani and Mishra, 2022b
included. As a result of applying these criteria in the end, 168 papers were included in the
literature review. Figure 5 shows the methodology to identify the barriers to the ISGLSAMS.
4. Barriers to ISGLSAMS
Even after awareness of SM, GM, LM, design for six sigma, AM and the methodology to
integrate these various strategies, many organizations fail to implement the ISGLSAMS due
to various barriers. This paper through literature review identifies various barriers and their
associated subclauses that hinder the organization to implement the ISGLSAMS and get the
desired outcomes. Table 1 shows the alphabetical list of the resources of the papers included
in the study. Figure 6 shows the year-wise distribution of the papers included in the study.
The following section describes the contribution of various authors to the various barriers.
Figure 5.
Identification of the barriers Four-step methodology
through papers which met research to identify the barriers
objective of the study to the ISGLSAMS
recovery through modular product design (Nnorom and Osibanjo, 2008), (4) lack of
compliance with environmental legislation (Muduli et al., 2013), (5) corruption and week
political support, (6) lack of clearly defined rules, lack of audit and monitoring (Ghose, 2003),
(7) lack of enforcement or lack of strict supervision, (8) changing regulations from changing
political environment (Abdullah et al., 2016; Muduli et al., 2013), (9) delay in decision-making
or lengthy legal procedures (Sharma et al., 2009) and (10) ineffective enforcement and an
inadequate monitoring mechanism (Mittal and Sangwan, 2014a) contribute to weak
legislation for the implementation of the ISGLSAMS.
(continued ) Table 1.
BIJ Journals Authors
Table 1. (continued )
Journals Authors
Barriers to the
adoption of
Staying Lean: Thriving, Not Just Surviving Hines et al. (2008) ISGLSAMS
The Global Manufacturing Revolution: Product-Process- Koren (2010)
Business Integration and Reconfigurable Systems
The ManuFuture road: Towards Competitive Jovane et al. (2009)
and Sustainable High-Adding-Value Manufacturing
Symposium
2011 IEEE International Symposium on Assembly and Koho et al. (2011)
Manufacturing (ISAM) Table 1.
Figure 6.
Year-wise distribution
of the papers included
in the study
The high initial cost of investment and long payback period (Mathiyazhagan et al., 2013)
cause organizations to seek government support for the fund for the ISGLSAMS.
4.7 Low customer awareness and demand for sustainable and agile products
(1) Lack of awareness about (a) SM practices (Shankar et al., 2017), (b) energy saving, and
emission reduction (Zhu and Geng, 2013), (c) environmental issues (Fargani et al., 2016), (d)
green products, processes and GM practices (Ghazilla et al., 2015), (e) GSCM (Abdullah et al.,
2016), (2) lack of customer demand about sustainable development and SM (Koho et al., 2011),
(3) lack of customers’ responsiveness to green products (Abdullah et al., 2016), (4) lack of
customer involvement or inadequate customer collaboration for (a) sustainable product
design and innovation and (b) low planet concern (Hoda et al., 2011) and (5) low customer
demand for reconfigurable products due to decreased rigidity (Fredriksson and Gadde, 2005)
lead to the barrier for the adoption of the ISGLSAMS.
4.12 Low top management commitment due to low awareness or negative attitude about the
ISGLSAMS
Poor commitment of senior level management in the transformation and other improvement
strategies (Hicks and Matthews, 2010) due to (1) poor knowledge (Kumar et al., 2016a) about
green products, green processes and GM practices and long-term benefits (Ghazilla et al.,
2015), (2) lack of environmental training and awareness programs (Ghazilla et al., 2015), (3)
lack of SM, concept and sustainability issues (Cherrafi et al., 2016), (4) lack of awareness about
framing these concepts within policymaking level (Kulatunga et al., 2013), (5) lack of
awareness regarding cost savings from (a) GSCM (Lee and Rhee, 2007), (b) reverse logistics,
recycling and reuse efforts and corporate social responsibility (Abdullah et al., 2016) and (c)
waste reduction and elimination of pollution, energy efficiency, prevention and mitigation of
accidents, (6) failure to identify the areas where these advanced technologies could be utilized
(Barve and Muduli, 2013), (7) lack of relevant information on market and new green
technologies (Abdullah et al., 2016), (8) lack of awareness about reconfigurable agile
technology (Yusuf et al., 1999), (9) lack of interest due to high technology risk (Ivansen et al.,
2019), (10) perception of huge amount of documentation work, (11) possibilities of social
outcry or even legal action upon disclosure of any serious noncompliance during the
environmental audit process (Quazi, 1999), etc. hamper management commitment for new
practices (Alefari et al., 2017; Barve and Muduli, 2013).
This causes management reluctance to allocate adequate financial, technological and
human resources (Cherrafi et al., 2017) for the implementation of sustainable green AM
practices (Amrina and Sha’ri, 2012; Hasan et al., 2007; Kaur et al., 2018; Lee and Rhee, 2007)
and to sustain the new program or concept (Wong et al., 2009a).
4.17 Lack of awareness, training, education and the reward system of employees
Lack of (1) awareness, knowledge and education of employees (Dhull and Narwal, 2016) about
(a) sustainable (Millar and Russell, 2011), (b) lean (Marodin and Saurin, 2015), (c) six sigma
(Aboelmaged, 2011), (d) environmental savvy (Cherrafi et al., 2017) and (e) green product and
services (Dhull and Narwal, 2016), (2) awareness about advanced manufacturing practices,
occupational health and safety hazards and protocols, (3) awareness about cost savings due
to GSCM (Muduli et al., 2013), (4) awareness about environmental impact of unsustainable
practices (Ghazilla et al., 2015), (5) awareness about reverse logistics and sustainability
benefits (Kaur et al., 2018; Kulatunga et al., 2013), (6) awareness of international trends in
legislation and markets with regard to the environmental aspects (Schaper, 2002), (7)
awareness about energy-saving and emission reduction (ESER) program for sustainable
production and consumption (Zhu and Geng, 2013), (8) no or insufficient continuous training,
education and reward system (Hasan et al., 2007), (9) training by professionals (Schein, 2004),
(10) specific domain training for white-collar managers and blue-collar workers for expertise
and execution (Machado, 2014), (11) rewards (Hsu and Hu, 2008) or recognition (Wyrwicka
and Mrugalska, 2017) for green employees, (12) compatibility of manufacturing strategy with
BIJ the company bonus or incentives systems (Machado, 2014), (13) rewards and penalty from the
government (Kulatunga et al., 2013), etc. do not motivate the employees and organization for
ISGLSAM practices. The presence of a reward system, training and awareness program
motivates the employees to learn and opt for ecological concepts (Hsu and Hu, 2008) and
enhances the commitment to the ISGLSAMS.
4.21 Difficulty in the evaluation of system performance throughout the life cycle
Various difficulties viz. (1) difficulty in quantifying the benefits upfront (Alefari et al., 2017), (2)
difficulty in finding information on environmental impact (Bey et al., 2013), (3) absence of
practical guidelines, the performance evaluation matrix and parameters to assess sustainable
performance and identify underperforming domains (Bhanot et al., 2016), (4) difficulty in
estimating quality, flexibility, competitive advantage and customer satisfaction (Henderson
et al., 2004), (5) difficulty in measuring agility performance (Prince and Kay, 2003), (6)
difficulty in measuring and monitoring suppliers’ environmental practices and performance
(Mathiyazhagan et al., 2013), (7) difficulty in tracing the carbon footprint (Raut et al., 2018) and
(8) difficulty in collection of the product, process and system data (Rahimifard et al., 2009) and Barriers to the
system performance measurement (Wyrwicka and Mrugalska, 2017) throughout the life adoption of
cycle, etc. create a major barrier for adoption of the ISGLSAMS.
ISGLSAMS
4.22 Lack of cooperation and mutual trust among management, employees and supply
chain partners
Due to a lack of cooperation, mutual trust, mistrust among management, employees, workers
(Machado, 2014; Marodin and Saurin, 2015), supply chain (Berger et al., 2018), and corporate
partners for new practices (Kumar et al., 2016b) and innovation (Abdullah et al., 2016), the
ISGLSAMS is difficult to implement.
literature
Table 2.
of barriers in the
Frequency of citation
Authors 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
(continued )
Authors 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
(continued )
ISGLSAMS
Barriers to the
adoption of
Table 2.
BIJ
Table 2.
Authors 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
(continued )
Authors 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
(continued )
ISGLSAMS
Barriers to the
adoption of
Table 2.
BIJ
Table 2.
Authors 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
(continued )
Authors 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Table 2.
BIJ Economic
ISGLSAMS ISGLSA Performance
Energy
Enablers or Product Design
practices
ISGLSA Market
Process Plan Performance
ISGLSAMS
Environmental
Barriers Performance
Material Usage
Remanufacturing
Recycling Wastes & Reuse
Extraction
Social
Emissions End of life
Performance
Anthro-sphere
Ecosphere
Environment
Economy Society
Energy
Material
Product
Figure 7. Wastes & Emissions
Research framework
for the ISGLSAMS
Note(s): Hariyani et al., 2022; Hariyani and Mishra, 2022c
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