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Corporate Lean Management: From implementation of lean — to the design of lean-based operations management systems
KTH, School of Industrial Engineering and Management (ITM), Production engineering.ORCID iD: 0000-0002-7038-2214
2025 (English)Doctoral thesis, comprehensive summary (Other academic)
Sustainable development
SDG 9: Industry, innovation and infrastructure, SDG 8: Decent work and economic growth, SDG 12: Responsible consumption and production
Abstract [en]

In today’s rapidly changing industrial landscape, multinational production corporations face considerable challenges in realising lasting performance improvements through lean management across their global production networks. Decades after the widespread implementation of lean, the critical challenge of how to manage and align local factory improvements with overarching corporate strategies for operational excellence remains. The complexity intensifies when companies attempt to manage large-scale lean transformations at a global corporation level, raising crucial questions about how such transformations are managed, adapted, and sustained over time. This thesis addresses this gap by examining how companies design, implement, and sustain corporate-level lean strategies—particularly through the management of company-specific production systems (XPSs). Through five in-depth qualitative studies conducted in large industrial production corporations, the research uncovers how practitioners face recurring obstacles characteristic of multisite lean implementation. The main themes that emerged concerned the need to invest in employee training and capability-building, while simultaneously achieving measurable performance improvements. While global standardisation of improvement tools is a common approach, it proves resource-intensive and often insufficient without embedding organisational learning principles and adaptability to local needs. The findings show that many organisations underestimate how chosen implementation strategies shape both immediate operational gains and the long-term development of organisational capabilities. To address these issues, the thesis makes several contributions. It describes four interrelated components central to managing multisite lean implementation and identifies four predominant types of implementation strategies — education, tool, pragmatic, and culture — each influencing organisational outcomes in distinct ways. The dynamic interplay and shifting among these implementation strategies are demonstrated to be essential in adapting to evolving implementation challenges and strategic priorities. Furthermore, an XPS capability framework is introduced, which elaborates programme actions to different problem areas encountered in corporate-level lean transformation. Six core XPS capabilities are identified, supporting companies to initiate, accelerate, and adapt their improvement efforts across global production networks. The research also advances theory by reconceptualising the role of XPS, not merely as a vehicle for diffusing operating values and improvement tools, but as a mechanism for deliberately redesigning the operations management system to a lean-based one. This positions the XPS as a dynamic mechanism through which investments in the programme accumulate as structural capital, providing the company with a competitive edge for future corporate-level transformations toward operational excellence. In addition, the thesis identifies and characterises several forms of ‘implementation waste’ unique to implementation in multisite contexts, providing both theoretical insight and actionable guidance. By highlighting these challenges and offering contextualised frameworks, this thesis contributes to the academic discourse on corporate lean management in an industrial production context, and effective realisation of global production operations strategy. It offers practical tools and concepts to guide practitioners in achieving more deliberate, flexible, and effective corporate lean management, ultimately supporting sustainable improvement across diverse industrial environments. 

Abstract [sv]

I dagens snabbt föränderliga industriella landskap står multinationella produktionsföretag inför betydande utmaningar med att uppnå hållbara prestationsförbättringar genom lean management i sina globala produktionsnätverk. Efter årtionden av lean implementeringen kvarstår den kritiska utmaningen att hantera och samordna lokala fabriksförbättringar med övergripande företagsstrategier för operationell excellence. Komplexiteten intensifieras när företag försöker hantera storskaliga lean-transformationer på global nivå, vilket väcker avgörande frågor om hur sådana transformationer hanteras, anpassas och upprätthålls över tid. Denna avhandling adresserar detta kunskapsgap genom att undersöka hur företag utformar, implementerar och upprätthåller lean-strategier på företagsnivå – särskilt genom hanteringen av företagsspecifika produktionssystem (XPS). Genom fem kvalitativa studier i stora industriella produktionsföretag visar forskningen hur praktiker möter återkommande hinder karakteristiska för implementering av lean inom koncerncer med flera produktionsfabriker. Forskningen visar att de centrala utmaningarna för företagen är hur de ska investera i anställdas utbildning och kapabiliteter, samtidigt som mätbara prestationsförbättringar skulle uppnås. Även om global standardisering av förbättringsverktyg är en vanlig praxis för implementering, visar det sig resurskrävande med ofta otillräcklig effekt där inlärningsprinciper och anpassning till lokala behov förbises. Resultaten indikerar även att många organisationer underskattar hur valda implementeringsstrategier formar både omedelbara operativa vinster och den långsiktiga utvecklingen av organisatoriska förmågor. För att adressera dessa utmaningar innehåller avhandlingen med flera kunskapsbidrag. Den beskriver fyra sammankopplade komponenter som är centrala för hantering av lean-implementering på koncernnivå och identifierar fyra dominerande typer av implementeringsstrategier – utbildning, verktyg, pragmatisk och kultur – som var och en påverkar organisatoriska utfall på olika sätt. Den dynamiska samverkan och växling mellan dessa strategier visas vara avgörande för att anpassa sig till föränderliga implementeringsutmaningar och strategiska prioriteringar. Avhandlingen introducerar även ett ramverk för XPS-kapabiliteter som specificerar programåtgärder för olika problemområden vid lean-transformation på företagsnivå. Ramverket identifierar sex centrala kapabiliteter för ledning av XPS, vilket stödjer företag att initiera, accelerera och anpassa förbättringsinsatser i deras globala produktionsnätverk. Forskningen bidrar även teoretiskt genom att omkonceptualisera XPS-rollen: från att inte enbart formulera värderingar och förbättringsmetoder, utan som en mekanism för medveten omstrukturering av operationsledningssystemet till ett lean-baserat system. Detta positionerar XPS som en dynamisk mekanism där investeringar ackumuleras som strukturellt kapital, vilket ger företaget konkurrensfördelar i framtida transformationer mot operationell excellens. Dessutom identifierar och karakteriserar avhandlingen flera former av "implementeringsslöseri" unika för implementering inom koncerner, vilket ger både teoretisk insikt och handlingsbar vägledning för praktiker. Genom att belysa dessa utmaningar och erbjuda kontextualiserade ramverk bidrar denna avhandling till den akademiska diskursen om företags lean management i industriell produktion samt effektiv realisering av globala produktionsoperationsstrategier. Den erbjuder praktiska verktyg och koncept för att vägleda praktiker mot mer avsiktlig, flexibel och effektiv företagslean management, vilket slutligen stödjer hållbar förbättring i olika industriella miljöer.  

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2025. , p. 114
Series
TRITA-ITM-AVL ; 2025:30
Keywords [en]
Lean management, implementation, operational excellence, corporate lean management, XPS, organisational change, implementation strategies, global production networks
Keywords [sv]
Lean Management, Implementering, Operationell Excellens, Lean Management på koncernnivå, Företagsspecifika produktionssystem (XPS), Organisationsförändring, Implementeringsstrategier, Globala produktionsnätverk
National Category
Engineering and Technology
Research subject
Production Engineering
Identifiers
URN: urn:nbn:se:kth:diva-368466ISBN: 978-91-8106-340-0 (print)OAI: oai:DiVA.org:kth-368466DiVA, id: diva2:1989284
Public defence
2025-09-12, Gradängsalen / https://kth-se.zoom.us/j/66235079341, Teknikringen 1, Stockholm, 10:00 (English)
Opponent
Supervisors
Available from: 2025-08-19 Created: 2025-08-15 Last updated: 2025-09-09Bibliographically approved
List of papers
1. Navigating implementation strategies: insights from XPS programmes
Open this publication in new window or tab >>Navigating implementation strategies: insights from XPS programmes
2024 (English)In: Journal of Manufacturing Technology Management, ISSN 1741-038X, E-ISSN 1758-7786, Vol. 36, no 9, p. 69-87Article in journal (Refereed) Published
Abstract [en]

Purpose: This study explores how industrial production companies adjust implementation strategies to deliver value with their company-specific production system (XPS) in a multi-site setting. Implementing an XPS is part of operations management and is supposed to mobilise employees resource-efficiently to increase operational performance. Design/methodology/approach: Based on a multiple-case study, this study qualitatively explores the patterns of implementation decisions within and between five multi-site production companies. Conclusions were drawn on a mix of timely and retrospective data gathered through individual interviews with senior managers and joint workshops where they interacted and shared experiences. Findings: This study identifies the fact that companies respond differently to non-unique implementation challenges, constituting various decision patterns when implementing their XPS. This paper identifies four implementation strategies (Education, Tool, Pragmatic and Culture Strategy) that explain various implementation setups. More experienced companies frequently shifted between strategies to return to previously de-prioritised implementation aspects. Originality/value: This paper offers a dynamic model for XPS implementation in contrast to a simplified tool–system–culture sequence in literature today. Companies that deliberately shift implementation strategy by understanding the benefits and challenges of their decisions are more likely to keep momentum in the XPS implementation.

Place, publisher, year, edition, pages
Emerald, 2024
Keywords
Corporate lean management, Implementation, Improvement programme, Production, XPS
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-359290 (URN)10.1108/JMTM-05-2024-0233 (DOI)001396939600001 ()2-s2.0-85215529291 (Scopus ID)
Note

QC 20250130

Available from: 2025-01-29 Created: 2025-01-29 Last updated: 2025-08-15Bibliographically approved
2. The Issue of Corporate Mandatory Standards in Production Improvement Programmes
Open this publication in new window or tab >>The Issue of Corporate Mandatory Standards in Production Improvement Programmes
2024 (English)In: Journal of Industrial Engineering and Management, ISSN 2013-8423, E-ISSN 2013-0953, Vol. 17, no 2, p. 385-402Article in journal (Refereed) Published
Abstract [en]

Purpose: This paper aims to explore and describe how companies manage the level of standardisation of improvement practices in a multisite context. It seeks to explain the managerial strategies applied to change the standardisation level in manufacturing companies with multiple production sites worldwide. Design/methodology/approach: This paper reports from a case based on data collected through semi-structured interviews, participant observations and company documents from a large multinational producing company and, specifically, from of the largest production sites in the company. The research design resembles a grounded theory approach by being reflexive and open to emerging themes. The standardisation strategy was analysed at a company that strived to increase the standardisation of problem-solving practices within about 20 production sites as part of their corporate lean programme. Findings: Several managerial tools were applied at the corporate level to increase the standardisation level of problem-solving practices, such as developing standards and a company-specific toolbox aligned with an in-house maturity model. In addition, deploying change leaders and global implementation targets enabled audits and progress. However, consequences at the production-site level became minor adaptations of standards, the design of training models as a “roll-out”, and a resource-demanding implementation process. Originality/value: This paper empirically demonstrates strategic tools that corporate management teams apply to influence the company’s standardisation level of practices. The study describes the purpose and consequences of the design of the toolbox, maturity model, training model, and implementation targets, which aims to simplify the complex task of managing standardisation in a corporate group. By applying a knowledge-based view, four processes (i.e. adaptation, integration, upskilling, and learning) were identified to improve the management strategies in multisite contexts.

Place, publisher, year, edition, pages
Omnia Publisher SL, 2024
Keywords
case study, grounded theory, knowledge management, lean management, level of standardization, multinational companies, XPS
National Category
Business Administration
Identifiers
urn:nbn:se:kth:diva-347278 (URN)10.3926/jiem.7182 (DOI)001228311500001 ()2-s2.0-85194357645 (Scopus ID)
Note

QC 20240612

Available from: 2024-06-10 Created: 2024-06-10 Last updated: 2025-08-15Bibliographically approved
3. Context-driven implementation strategies: Exploring three approaches to implement a lean capability framework within a global production company
Open this publication in new window or tab >>Context-driven implementation strategies: Exploring three approaches to implement a lean capability framework within a global production company
2024 (English)In: Knowledge and Process Management, ISSN 1092-4604, E-ISSN 1099-1441, Vol. 31, no 4, p. 345-358Article in journal (Refereed) Published
Abstract [en]

This paper explores global implementation of capability building projects as part of an corporate lean programme. The aim is to identify the core parameters in global implementation of complex knowledge in various contexts within the corporation. The empirical research investigates the global implementation of a lean capability project in three regional clusters within a large pharmaceutical multinational production company. The findings indicate that contextual situations in regional clusters, for example, maturity levels, national culture, and previous experiences, influence the design of the implementation approaches embedding knowledge management principles in various ways. Three types of implementation approaches (horizontal, parallel, and delegated) are identified, which highlights the strategically different pathways to realise new frameworks for knowledge management. This study shows how adjustments to contextual situations influence the implementation process and identifies various hallenges with various approaches that may hinder the execution of lean strategy. This paper puts forward five identified implementation parameters that could guide future research and knowledge management practitioners in opex, HR, and learning and development functions.

Place, publisher, year, edition, pages
Wiley, 2024
National Category
Business Administration Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:kth:diva-366728 (URN)10.1002/kpm.1790 (DOI)001313904900001 ()2-s2.0-85204226843 (Scopus ID)
Note

QC 20250709

Available from: 2025-07-09 Created: 2025-07-09 Last updated: 2025-08-15Bibliographically approved
4. Decoding Operational Excellence: How multisite production companies develop programme capabilities
Open this publication in new window or tab >>Decoding Operational Excellence: How multisite production companies develop programme capabilities
(English)Manuscript (preprint) (Other academic)
National Category
Engineering and Technology
Research subject
Industrial Engineering and Management
Identifiers
urn:nbn:se:kth:diva-368465 (URN)
Note

QC 20250815

Available from: 2025-08-15 Created: 2025-08-15 Last updated: 2025-08-15Bibliographically approved

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Linderson, Sara

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