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In today’s competitive world, industry needs to act in a proficient manner for its survival and sustenance. It is imperative for the top management to be ceased with the problems and understand factors associated with lean and efficient functioning, uncertainties, fluctuations and challenges posed by the competitors and environment (Chauhan et al., 2007; Zhou and Ji, 2020). Management of essential manufacturing flexibilities namely, labour flexibility, volume flexibility, machine flexibility, product flexibility, material handling flexibility and routing flexibility take care of operational and functional aspects of manufacturing firms and enable managers to deal with uncertainties systematically (Sethi and Sethi, 1990; Koste et al. 2004; Chauhan and Singh, 2013, Solke and Singh, 2018). These manufacturing flexibilities comprise of number of factors bearing inter relations affecting each other and consequently the lean manufacturing. It is difficult for any manager to understand and systematically analyse large number of factors that have complex relationships. Total Interpretive Structural Modelling (TISM) technique is a method developed for analysis of complex factors (Dubey and Ali 2014; Jena et al., 2017; Singh et al., 2018, Sharma et al., 2020). TISM has been applied, in the present study, for analysis and the data has been used for developing the model for two firms that differ from each other with regard to automation and working culture. Two companies chosen for study are involved in the production of different kind of products for automotive industry. One company is manufacturing assemblies and subassemblies of power source for generators of various capacities and types. Automation level in this company is higher than that of the other company involved in manufacture of composite parts which are manufactured to suit customers’ needs. The second company is more dependent on human skills. These companies were chosen for the study to assess the effect of working culture, organisation and methodology on lean performance using TISM. Use of TISM enables systematic analysis of relations between the factors affecting manufacturing flexibility and lean manufacturing. Factors pertaining to manufacturing flexibility affecting lean manufacturing have been identified from the review of literature and in consultation with industry experts. Interrelations among these factors have been analyzed using TISM (Patil and Suresh, 2019) and used to identify dependent and driving parameters in both the companies. Parameters so identified would help in understanding the dynamics of interplay of factors depending on the nature of industry, technology employed, automation level and the and culture of functioning in the industry. Understanding of the factors and enablers in correct perspective by managers at appropriate level would not only assist lean implementation and enhance lean performance (Sushil, 2012; Chaple et al., 2018) but also enable sustenance of companies and withstand fierce competition. As such “sustainable manufacturing practices are essential for automotive component manufacturing organisation to ensure competitive advantage” according to Thirupati and Vinod, 2016 and sustainability along with lean enhancement would accrue synergetic effects in long term for the manufacturing companies.
Thus objective of this research work is to identify, understand and analyse complex factors of lean manufacturing and essential manufacturing flexibility having inter relations with each other using TISM technique and its application through case studies in two companies of different level automation, organizational structure and ethos of working and evolve parameters to be focused on by the managers for enhanced lean performance. Significance of the outcome of analysis is that the managers in the industry will be able to stress identified key areas and apply knowledge for enhanced lean performance and sustenance in the competitive market.