Authors: Assistant Professor Dr. M. Ravichandran, Sanjeeve
Abstract: This study explores the adoption and effectiveness of lean manufacturing practices among small and medium-sized enterprises (SMEs) in India. The primary objectives were to assess the extent of lean tool implementation—specifically 5S, Kaizen, Kanban, and Value Stream Mapping—evaluate their impact on operational efficiency and waste reduction, and identify key challenges faced by SMEs in adopting these practices. Data collected from 202 respondents across various Indian manufacturing SMEs was analyzed using descriptive and correlation methods. The findings indicate a moderate level of lean adoption, with employee training being the most emphasized aspect. However, integration into daily routines and management support remain limited. A statistically significant yet weak correlation was found between employee training and reduction in production cycle time, while other lean tools did not show notable direct impact on operational outcomes. The study concludes that while lean awareness exists, its practical impact is hindered by incomplete implementation and organizational constraints, emphasizing the need for stronger leadership, structured integration, and capacity building.
