Sustainable Agility Culture—The Case of a Pasta Company
Abstract
:1. Introduction
2. Problems of Changed Productivity in the Pasta Company
- Productivity of work per shift, that is, the productivity of work per shift, determined by dividing the total amount of work performed in a given month by the number of employees working on a given shift. The productivity value in this case will be given in kilograms of packed pasta per employee per shift.
- Total productivity in a month determined, as the sum of the amount of work performed by all shifts in a given month and dividing by the total number of employees working in all shifts in the same month. The productivity value, like the productivity of work per shift, will be given in kilograms of packed pasta per worker.
- The manual packaging process of pasta causes shortages that manifest as damaged/crushed product, which is withdrawn from the commodity distribution chain at the quality control stage.
- Frequent production interruptions, machine breakdowns, or technical problems caused production losses, which included a reduced number of kilograms of packed pasta.
- An insufficient number of trained employees could lead to insufficient productivity and generate losses.
- Packing teams on individual shifts were improperly organized—teams with very high productivity and very low relative productivity compared to the average value of this parameter were observed.
- The large assortment of the plant producing and packing pasta, which causes frequent changes in the organization of production, as well as the need to rearm machines and adapt the packing process to the type of pasta.
3. Research and Discussion
3.1. Methodology of the Test—Case Study
- What is the nature of the identified production problems?
- What are the main challenges of agile and sustainable manufacturing?
- What agile methods can be helpful for the identified problems?
- What are the ways and practices to shape an agile culture?
- How will agile management methods align with sustainability goals?
3.2. Results of Experts Survey
- -
- Limited resources that make it difficult to invest in equipment and packaging technology, as well as difficulty allocating funds for research and development, which limits their ability to bring innovation and new products to market.
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- Little ability to take advantage of economies of scale, making it difficult to compete on price with larger competitors.
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- Challenges of quality control, and the constant raising of standards and the need to use manual labor during inspections.
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- Seasonality and fluctuations in demand—the need to meet variable demand requires more flexible structures, relying heavily on the human factor.
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- The need to achieve sustainability goals and reduce environmental impact can challenge small companies with limited resources to invest in environmentally friendly practices and technologies.
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- The need to change organizational culture, which can be a particular problem for employees/companies with a traditional approach to manufacturing.
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- The role of communication and coordinating the activities of different departments and teams to ensure smooth communication (including from the bottom up) are key to agile manufacturing. This is especially difficult if the company previously operated in a more hierarchical manner.
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- The need to use the right techniques and methods, and the conviction to use them.
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- Adequate change management to overcome the resistance of employees and decision-makers, while encouraging the active use of the tools being implemented.
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- Scrum, which is an agile project management methodology based on flexible iterations in which a team works on a specific set of tasks, enabling adaptation to changing conditions and continuous process improvement.
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- Lean manufacturing, which is a production management methodology focused on eliminating waste, optimizing workflow, and delivering value to the customer by minimizing resources and production time.
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- Kanban, which is a work process management method based on a visual board that allows for monitoring the flow of tasks through various stages, thus, optimizing efficiency and reducing waste during scheduled tasks.
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- Shu Ha Ri, which is a development model in the context of learning and mastery, including three phases: Shu (learning and following the rules), Ha (deviating from the rules to explore) and Ri (transforming into an author and creating your own rules), often used in agile work methodologies.
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- Continuous improvement, which mainly involves improving processes and practices based on analysis of the results achieved and the reactions of customers and users of the product.
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- Collaboration, which means promoting teamwork, sharing knowledge and skills, and striving to solve problems as a group.
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- Communication, which will mainly involve the exchange of information, ideas, and opinions, contributing to a better understanding of the company’s goals and solving problems that arise at the pasta packaging stage.
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- Transparency of the enterprise’s operations, which allows building trust within the team of employees and enables joint decision making as a group.
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- Adaptation of introduced changes in the enterprise and adaptation to new requirements, which allows flexible response to changing working conditions, such as a turbulent environment.
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- Trust and respect, such as showing respect for diversity of opinions and developing the ability to listen and understand the perspectives of other members of the production team.
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- A leader as a guide who exemplifies an agile culture in practice, i.e., applying the values and best practices adopted for agility in the enterprise.
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- Reducing waste—agile methods encourage the identification and elimination of waste in production processes, which has a direct impact on efficiency and the reduction in negative environmental impacts.
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- Adapting to changes in a turbulent SME environment—sustainability requires the ability to respond quickly to changing conditions, and agile methods enable operations to adapt in response to new challenges, such as regulatory changes or market trends.
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- Innovative solutions—agile management methods promote collaboration, creativity, and innovation, which can lead to the development of more sustainable solutions and products, which the company will then offer to the market.
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- Team responsibility—sustainability requires the involvement of every team member, and agile methods emphasize responsibility and self-reliance, which contributes to building a strong and responsible company culture.
3.3. Changes in the Company by Agile Methodology
- Thoroughly training employees in standard packaging procedures to ensure uniformity and quality in the performed operations.
- Creation of clear packaging instructions to guide each employee.
- Supervision and support from more experienced leaders to help implement and solidify packaging standards.
- Analyzing packaging process productivity data to identify areas for improvement.
- Conducting causal analysis, such as an Ishikawa diagram (cause-and-effect diagram), to understand why problems occur in the packaging process.
- Implementing new technologies or tools that can automate or improve certain steps of packaging.
- Experimenting with different packaging approaches to find more efficient ways of working.
- Encouraging employees to share their ideas and suggestions for improvements in the packaging process.
- Creating a culture of continuous improvement in which every employee is involved in identifying and solving problems.
- Establishing regular reviews of the packaging process to monitor performance and look for new opportunities for optimization.
- Investing in developing the competence of employees to become leaders in their areas of responsibility and innovation.
4. Estimation of Significance Level of Productivity Factors in Terms of Agility Culture
5. Conclusions
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Month | No of Employees Shift 1 | Work Productivity—Shift 1 | No of Employees Shift 2 | Work Productivity—Shift 2 |
---|---|---|---|---|
January | 42 | 163.01 | 15 | 155.04 |
February | 52 | 177.05 | 14 | 178.44 |
March | 45 | 214.20 | 13 | 205.77 |
April | 30 | 225.83 | 10 | 158.52 |
May | 55 | 176.78 | 18 | 184.33 |
June | 49 | 251.16 | 31 | 170.90 |
July | 45 | 260.73 | 31 | 150.48 |
August | 44 | 271.36 | 27 | 194.07 |
September | 23 | 280.10 | 25 | 191.67 |
October | 23 | 403.09 | 13 | 358.38 |
November | 67 | 764.69 | 33 | 660.29 |
December | 52 | 256.94 | 19 | 454.42 |
Criterion/Methods | Scrum | Lean Manufacturing | Kanban | Shu Ha Ri |
---|---|---|---|---|
Difficulty of implementation | Introducing Scrum in a pasta company can be difficult, especially if there is already an established production process. Change may be met with resistance from the team. | Implementing lean manufacturing in a pasta producing and packaging company can be a challenge that requires careful planning and commitment of the entire team. | Implementing Kanban in a pasta company may be simple, but it requires proper preparation and team involvement. | The use of the Shu Ha Ri methodology requires the use of three basic steps, during which the company will focus on compliance with pasta packaging standards, then open up to innovations in this area and develop its own solutions. |
Time-consumption | The Scrum methodology is not time-consuming in itself, but the way it is implemented, and its complexity, can affect how long it will take to fully implement and manage the project in pasta company. | Implementing lean manufacturing can be time-consuming, but the benefits in terms of increased efficiency, reduced costs, and improved product quality can be significant. | Implementing Kanban in a pasta manufacturing and packaging company can be relatively time-consuming, but the time required for implementation depends on several factors, including the size of the company, existing processes, and the level of preparation of the team. | Implementation the Shu Ha Ri methodology into a pasta manufacturing and packaging company can be time-consuming because the approach requires specific development and evolution steps that occur gradually. |
Difficult to use at the packaging stage | Scrum introduces regular meetings, such as weekly sprint meetings. In the case of pasta production, where the process may be more constant, these meetings may be considered unnecessary and time-consuming. | Difficulties related to the implementation of lean manufacturing in the food industry may result from several factors (organizational culture, existing processes, striving for improvement in the production process), but with the right approach they can be overcome. | The use of Kanban at the packaging stage in a pasta manufacturing and packaging company is usually easy to implement because Kanban is a workflow management tool that is simple in its conception and application at the production stage. | Using the Shu Ha Ri methodology at the packaging stage in a pasta production and packaging company can be difficult because this approach involves gradual development and changes in the packaging process. |
Management/owner involvement | Successful Scrum implementation requires full commitment from the pasta company’s management, which can be difficult to achieve. | The implementation of lean manufacturing requires the involvement of the entire team and company management. This may be difficult to achieve. | Kanban at the packaging stage in a company producing and packaging pasta may require the involvement of the owner or management, which mainly involves supporting the process of change in the company. | Shu Ha Ri is an approach that assumes gradual development and changes in the approach to the process, and the involvement of management is important and necessary for the entire process to end with a positive change. |
Flexibility | Scrum allows users to adapt the project to changing market and customer conditions. In the case of pasta production, users can easily adapt to changing consumer preferences. | Lean manufacturing, by its nature, focuses on eliminating waste and optimizing production processes to increase efficiency and reduce costs. Although lean manufacturing can be adapted to a variety of industries, including pasta production and packaging, the flexibility of the method depends on how it is implemented and adapted to the specific company and its needs. | The use of Kanban at the stage of pasta production and packaging can help increase the company’s flexibility to some extent, but the Kanban method itself does not guarantee flexibility. Flexibility depends on how Kanban is implemented and adapted to the company’s specific situation. | The use of Shu Ha Ri in the production and packaging of pasta can help increase the company’s agility, but it is worth understanding that flexibility is not an automatic result of this approach. Flexibility depends on many factors, including how Shu Ha Ri is implemented and what changes are made. |
A clearly defined goal | Scrum requires that project goals are clearly defined and understood by the entire team. This can help avoid confusion and misunderstandings in the pasta company. | Lean manufacturing can help clearly define goals in the pasta production and packaging process. As part of a lean approach, defining and communicating goals is a key element that helps the team focus on delivering customer value and eliminating waste. | The use of Kanban at the pasta production and packaging stage can help to clearly define production and work management goals, but Kanban itself is not a tool for defining goals. Kanban is a workflow management method that helps users to control and monitor production processes and manage tasks visually and efficiently. | Shu Ha Ri is an approach based on personal development and process improvement. Although not directly related to goal setting, it can help to understand what goals and changes are needed in the organization (pasta company). |
Team commitment | Scrum promotes team commitment and accountability for achieving project goals. In the case of pasta production, this can help to improve product quality and production efficiency. | Lean manufacturing can have a positive impact on the involvement of the pasta production and packaging team through greater responsibility and commitment of workers, understanding their goals, and continuous improvement. | Team commitment depends on many factors, including management’s approach, the organizational culture, and the way Shu Ha Ri is implemented. | |
Regular inspection of the methodology used | Scrum requires regular design reviews and adjustments. In the case of a company producing pasta, the production process can be constantly adjusted to changing conditions. | Lean manufacturing is a process of continuous improvement. Companies must constantly analyze and adapt their processes, which can be demanding. | The use of Kanban at the stage of pasta production and packaging is not in itself a tool that clearly defines the team’s commitment. Team engagement depends on many factors and must be monitored using other tools. | Team involvement is a matter of organizational culture, personnel management, and communication in the company. However, Shu Ha Ri can have a positive impact on the production team’s level of commitment. |
Criterion/Methods | Weights | Scrum | Lean Manufacturing | Kanban | Shu Ha Ri |
---|---|---|---|---|---|
Difficulty of implementation | 10 | 4 | 3 | 1 | 2 |
Time-consuming | 15 | 3 | 4 | 1 | 2 |
Difficult to use at the packaging stage | 25 | 4 | 3 | 1 | 2 |
Management/owner involvement | 5 | 4 | 3 | 2 | 1 |
Flexibility | 10 | 3 | 2 | 4 | 1 |
A clearly defined goal | 10 | 3 | 2 | 4 | 1 |
Team commitment | 15 | 4 | 3 | 2 | 1 |
Regular inspection of the methodology used | 10 | 4 | 3 | 1 | 2 |
Sum | 365 | 295 | 180 | 160 |
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Bartkowiak, A.; Butlewski, M. Sustainable Agility Culture—The Case of a Pasta Company. Sustainability 2023, 15, 16540. https://doi.org/10.3390/su152316540
Bartkowiak A, Butlewski M. Sustainable Agility Culture—The Case of a Pasta Company. Sustainability. 2023; 15(23):16540. https://doi.org/10.3390/su152316540
Chicago/Turabian StyleBartkowiak, Agnieszka, and Marcin Butlewski. 2023. "Sustainable Agility Culture—The Case of a Pasta Company" Sustainability 15, no. 23: 16540. https://doi.org/10.3390/su152316540
APA StyleBartkowiak, A., & Butlewski, M. (2023). Sustainable Agility Culture—The Case of a Pasta Company. Sustainability, 15(23), 16540. https://doi.org/10.3390/su152316540