Enhancing overall equipment effectiveness through lean digitization: a longitudinal study in tractor manufacturing

Purpose In the modern world of ever-growing technologies, manufacturing organizations are improving productivity by implementing the synergy of lean principles and modern digital technologies. The research aims to explore the impact of Lean Digitization on Overall Equipment Effectiveness (OEE) in tractors and their parts manufacturing organizations. Design/methodology/approach The study employs a mixed-methods approach, integrating both quantitative and qualitative techniques to examine the impact of lean digitization on OEE. It analyzes weekly OEE data over three years: pre-digitization, immediately post-digitization and eight years after implementation. Quantitative analysis involves Paired T-tests for pre- and post-digitization comparison. Qualitative insights are drawn from interview responses to validate and complement the quantitative findings, ensuring a comprehensive understanding of lean digitization’s effects on OEE. Findings The results of this study show a maximum of 18% improvement in OEE after the implementation of lean digitization initiative with a prominent dominance of performance parameters of OEE in both quantitative and qualitative phases. Practical implications It not only helps in gauging the impact and its significance but also contributes to the existing literature of lean manufacturing and digital transformations by reflecting the multi-dimensional aspects of lean digitization impacts including technician behavior, change acceptance, work complexity, etc. Originality/value The literature depicts different techniques, i.e. Total Productive Maintenance, Lean Technologies, Real-Time Monitoring, etc. aiming to improve operational efficiency. However, the footprints of this synergy on equipment performance are still unknown in tractor manufacturing industries, which are covered in this study.