Exploring the Adoption of Lean Manufacturing and Its Influence on Operational Performance: A Case Study of Dangote Cement Factory

Lean manufacturing has transformed from being more than just a production philosophy advocated by Toyota to an international approach to efficiency, waste reduction and competitiveness. Although lean practices have been organized in developed economies like Japan, the United States, and the United Kingdom, their use in developing economies has not been widely addressed, especially in the context of the manufacturing industry in Nigeria. The current study examined the impact of lean manufacturing on the operational performance of Dangote Cement Factory, which is one of the largest industrial companies in Nigeria. Quantitative research design was adopted whereby the survey strategy was adopted whereby structured questionnaires were administered to the operational staff. Based on the estimated sample size, 94% of the responses were obtained and analyzed using IBM SPSS and the PROCESS macro.

Lean Manufacturing, Operational Performance, Kaizen, Value Stream Mapping

1. Abioye, T. E. & Bello, E. I., 2012. A Review of Awareness and Implementation of Lean Manufacturing within Nigerian Small-Scale Manufacturing Companies. Journal of Mechanics Engineering and Automation, 2(1), pp. 374-380. [Google Scholar] [Crossref]

2. Ahmad, N., Alias, F. A., Hamat, M. & Mohamed, S. A., 2024. Reliability analysis: application of Cronbach’s alpha in research instruments. Sig : e-Learning@CS, 1(1), pp. 114-120. [Google Scholar] [Crossref]

3. Aka, A., Isah, A. D., Eze, C. J. & Timileyin, O., 2020. Application of lean manufacturing tools and techniques for waste reduction in Nigerian bricks production process. Engineering, Construction and Architectural Management, 27(3), pp. 1-15. [Google Scholar] [Crossref]

4. Alanya, B. S., Dextre, K. E., Núñez, V. & Marcelo, G., 2020. Improving the Cutting Process Through. IEEE International Conference on Industrial, 1(1), pp. 1-20. [Google Scholar] [Crossref]

5. Ali, T. U. & Abdulraheem, I., 2025. Effect of supply chain management practices on the performance of Dangote cement company Obajana, Kogi state. Abuja Journal of Business and Management (AJBAM), 3(1), pp. 298-312. [Google Scholar] [Crossref]

6. Alshammari, S. et al., 2025. Impact of Total Quality Management and Lean Manufacturing on Sustainability Performance: An SEM-ANN Approach in Saudi Food Manufacturing. Sustainability, 17(5), pp. 21-39. [Google Scholar] [Crossref]

7. Andersson, M., Boateng, K. & Abos, P., 2024. Validity and Reliability: The extent to which your research findings are accurate and consistent, Taipei: Tunneling and Trenchless Technology. [Google Scholar] [Crossref]

8. Antonio, A., 2024. Lean Manufacturing and Its Impact on Production Efficiency. Journal of Research in International Business and Management, 11(3), pp. 1-2. [Google Scholar] [Crossref]

9. Azubuike, P., 2025. Data Science and the Smart Manufacturing Revolution: A New Era for Nigeria’s Industrial Growth. [Online] Available at: https://dailytrust.com/data-science-and-the-smart-manufacturing-revolution-a-new-era-for-nigerias-industrial-growth/ [Accessed 19 September 2025]. [Google Scholar] [Crossref]

10. Bayode, O. T. & Duarte, A. P., 2022. Examining the Mediating Role of Work Engagement in the Relationship between Corporate Social Responsibility and Turnover Intention: Evidence from Nigeria. Administrative Sciences, 12(4), pp. 150-165. [Google Scholar] [Crossref]

11. Budriene, D. & Diskiene, D., 2020. Employee engagement: types, levels and relationship with practice of hrm. Malaysian E Commerce Journal (MECJ) , 4(2), pp. 42-47. [Google Scholar] [Crossref]

12. Bu, X. et al., 2022. Proposing Employee Level CSR as an Enabler for Economic Performance: The Role of Work Engagement and Quality of Work-Life. Sustainability, 14(3), p. 1354. [Google Scholar] [Crossref]

13. Choudhary, S., Nayak, R. D. M. & Mishra, N., 2019. An integrated lean and green approach for improving sustainability. Production Planning & Control, 1(1), pp. 1-15. [Google Scholar] [Crossref]

14. Conţu, E. G., 2020. Organizational performance – theoretical and practical approaches; study on students’ perceptions. Proceedings of the International Conference on Business Excellence , 14(1), pp. 398-406. [Google Scholar] [Crossref]

15. Crawford, M., 2016. 5 Lean Principles Every Engineer Should Know, s.l.: ASME. [Google Scholar] [Crossref]

16. Dangote Cement Plc, 2020. Annual Report 2020, s.l.: Dangote. [Google Scholar] [Crossref]

17. Dutta, S., 2023. The Theory of Constraints: A Framework for Enhancing Efficiency and Promoting Growth. American international Journal of Business Management (AIJBM), 6(12), pp. 36-44. [Google Scholar] [Crossref]

18. Dziuba, S. T., Ingaldi, M. & Zhuravskaya, M., 2020. Employees’ Job Satisfaction and their Work Performance as Elements Influencing Work Safety. System Safety Human - Technical Facility - Environment , 2(1), pp. 18-25. [Google Scholar] [Crossref]

19. Feld, W. M., 2001. Lean manufacturing : tools, techniques, and how to use them. United States of America: The St. Lucie Press/APICS Series on Resource Management. [Google Scholar] [Crossref]

20. Flores-Meza, S., Limaymanta-Perales, J., Eyzaquirre-Munarriz, J. & Perez, M., 2020. Lean Manufacturing Model for production management to increase SME productivity in the non-primary manufacturing sector. The 9th AIC 2019 on Sciences & Engineering (9thAIC-SE), 79(6), pp. 1-9. [Google Scholar] [Crossref]

21. goVIMANA, 2025. What are lean manufacturing tools?. [Online] Available at: https://www.google.com/imgres?q=lean%20tools&imgurl=https%3A%2F%2Fgovimana.com%2Fwp-content%2Fuploads%2Felementor%2Fthumbs%2Flean-manufacturing-tools-v2-min-poa2tddcx1o8wtdnbmb46m3fbhco4j1mxwxyifbhfc.png&imgrefurl=https%3A%2F%2Fgovimana.com%2Flean-manufac [Accessed 19 September 2025]. [Google Scholar] [Crossref]

22. Habib, M. A., Rizvan, R. & Ahmed, S., 2023. Implementing lean manufacturing for improvement of operational performance in a labeling and packaging plant: A case study in Bangladesh. Results in Engineering, 17(1), pp. 1-20. [Google Scholar] [Crossref]

23. Hameed, U., 2024. Qualitative Data Analysis, s.l.: University of Liverpool. [Google Scholar] [Crossref]

24. Handoyo, S., Suharman, H., Ghani, E. K. & Soedarsono, S., 2023. A business strategy, operational efficiency, ownership structure, and manufacturing performance: The moderating role of market uncertainty and competition intensity and its implication on open innovation. Journal of Open Innovation: Technology, Market, and Complexity, 9(2), pp. 1-15. [Google Scholar] [Crossref]

25. Henao, R., Sarache, W. & Jimenez, I. D. G., 2019. Lean Manufacturing and Sustainable Performance: Trends and Future Challenges. Journal of Cleaner Production 208, 1(1), pp. 1-15. [Google Scholar] [Crossref]

26. Hennink, M. & Kaiser, B. N., 2022. Sample sizes for saturation in qualitative research: A systematic review of empirical tests. Social Science & Medicine, 292(1), pp. 1-15. [Google Scholar] [Crossref]

27. Herry, A. P., Farida, F. & Adesta, E. Y. T., 2022. The Effect of Lean Waste Reduction Technique to Business Results:a Confirmatory Study. Management and Production Engineering Review, 13(2), pp. 92-101. [Google Scholar] [Crossref]

28. Hwang, G., Han, S., Jun, S. & Park, J., 2014. Operational Performance Metrics in Manufacturing Process: Based on SCOR Model and RFID Technology. International Journal of Innovation, Management and Technology, 5(1), pp. 50-56. [Google Scholar] [Crossref]

29. Ikimi, N. U. & Anosike, A. N., 2024. The Nigeria Government Engagement with the Private Health Sector. Open Journal of Stomatology, Volume 14, pp. 235-248. [Google Scholar] [Crossref]

30. ILO, 2017. Lean Manufacturing Techniques For Textile Industry, s.l.: International Labour Organization. [Google Scholar] [Crossref]

31. Inuwa, M., 2024. Laying Foundation for Lean Manufacturing Implementation within Small and Medium Sized Enterprises in Nigeria: An Analysis of Change Readiness. International Journal Of Economics And Management Review, 10(1), pp. 88-116. [Google Scholar] [Crossref]

32. Inuwa, M. & Usman, A., 2022. Prospects and Challenges of Lean Manufacturing Deployment within Manufacturing SMEs in Nigeria: A Literature Review. Journal of Social Sciences and Management Studies, 1(1), pp. 51-55. [Google Scholar] [Crossref]

33. Järvenpää, E. & Lanz, M., 2020. Lean Manufacturing, s.l.: Tampere University of Technology. [Google Scholar] [Crossref]

34. John, O. E., 2024. Awareness and Willingness to Adopt Lean Technology among Micro Small Medium Enterprises in Nigeria. American Journal of Industrial and Business Management, 14(3), pp. 283-295. [Google Scholar] [Crossref]

35. Kayode, O., 2024. Effect of lean manufacturing practices on supply chain performance in food and beverage manufacturing firms in nigeria. African Journal of Emerging Issues (AJOEI)., 6(12), pp. 1-23. [Google Scholar] [Crossref]

36. Khanday, S. A. & Khanam, D., 2019. THE RESEARCH DESIGN. Journal of critical reviews, 6(3), pp. 367-390. [Google Scholar] [Crossref]

37. KPMG, 2023. Manufacturing sector: A Key Driver for Prosperity and Economic Development in Nigeria, Lagos: KPMG. [Google Scholar] [Crossref]

38. Leroyal, C., 2024. Critical realism. EBSO, 1(1), pp. 1-15. [Google Scholar] [Crossref]

39. Linus, O. O. & Daud, W. N. W., 2020. The Impact of Lean Production and Flexible Manufacturing Strategies on Financial Performance of Manufacturing Companies in Nigeria. Journal of Management Theory and Practice (JMTP) , 1(3), pp. 90-110. [Google Scholar] [Crossref]

40. Longhi, C. et al., 2018. Innovative Learning Approaches for Implementation of Lean Thinking to Enhance Office and Knowledge Work Productivity, s.l.: Erasmus. [Google Scholar] [Crossref]

41. Marikyan, D. & Papagiannidis, S., 2025. Unified Theory of Acceptance and Use of Technology. A review. In S. Papagiannidis (Ed), 1(1), pp. 1-16. [Google Scholar] [Crossref]

42. Maware, C., Okwu, M. O. & Adetunji, O., 2020. A systematic literature review of lean manufacturing implementation in manufacturing‐based sectors of the developing and developed countries. 1(1), pp. 1-15. [Google Scholar] [Crossref]

43. Maware, C. & Parsley, D., 2022. The Challenges of Lean Transformation and Implementation in the Manufacturing Sector. Sustainability, 14(10), pp. 62-87. [Google Scholar] [Crossref]

44. Moneme, P., 2016. Lean business strategy and performance of Nigerian manufacturing sector, 1990 - 2014, s.l.: Nnamdi Azikiwe University. [Google Scholar] [Crossref]

45. Moneme, P., 2016. Lean business strategy and performance of Nigerian manufacturing sector, 1990-2014, s.l.: s.n. [Google Scholar] [Crossref]

46. Moore, E., 2017. Overcoming the challenges of the manufacturing sector in nigeria and the outlook for 2017, Lagos: Manufacturing & Equipment Expo Nigeria 2017. [Google Scholar] [Crossref]

47. Nwanya, C. & Oko, A., 2019. The limitations and opportunities to use lean based continuous process management techniques in Nigerian manufacturing industries – a review. Journal of Physics Conference Series, 1(1), pp. 1-15. [Google Scholar] [Crossref]

48. Ohiomah, i., 2015. Lean Manufacturing Adoption and Implementation in Nigeria Manufacturing Industries. Operations and supply chain management, 1(1), pp. 1-15. [Google Scholar] [Crossref]

49. Ohiomah, I. & Aigbavboa, C., 2015. Lean manufacturing adoption and implementation in Nigeria manufacturing industries. 2015 sustainable industrial processing summit, Volume 11, pp. 385-400. [Google Scholar] [Crossref]

50. Okafor, G. O., Agbata, A. E., Nnubia, I. C. & Sunday C. Okaro, 2023. Corporate Social Responsibility and the Impact of COVID-19 on Healthcare Institutions in Nigeria. CSR, Sustainability, Ethics & Governance, pp. 279-296. [Google Scholar] [Crossref]

51. Okolocha, C. & Anugwu, C. C., 2022. Lean Manufacturing Approach and Operational Efficiency of Nigerian Pharmaceutical Companies in Anambra State. Saudi Journal of Business and Management Studies, 7(3), pp. 94-99. [Google Scholar] [Crossref]

52. Oladipupo, O., Durodola, O. I. & Falana, O., 2022. A Review of Kaizen/Continuous Improvement and its Relevance to Improving Operations. INSY , pp. 1-20. [Google Scholar] [Crossref]

53. Ologbon, E. G. & Adekunle, O. K., 2024. The impact of lean manufacturing techniques on waste reduction in Guinness Nigerian plc. Journal of the Management Sciences, 61(9), pp. 422-437. [Google Scholar] [Crossref]

54. Olu-Lawal, K. A., Ekemezie, I. O. & Usiagu, G. S., 2024. Lean manufacturing in industrial engineering: A USA and African review. GSC Advanced Research and Reviews, 18(02), pp. 225-233. [Google Scholar] [Crossref]

55. Onye, K. U. & Etuk, S. M., 2023. On the Manufacturing Sector Performance and Nigeria's Economic Growth. International Journal of Social Sciences, 1(1), pp. 79-90. [Google Scholar] [Crossref]

56. Owan, J. O., Ifere, E. O. & Odey, F. I., 2024. The Impact of Manufacturing Output On Employment in Nigeria. International Journal of Developing and Emerging Economies, 1(2), pp. 1-23. [Google Scholar] [Crossref]

57. Panwar, A., Jain, R., Rathore, A. P. S. & Nepal, B., 2018. The impact of lean practices on operational performance – an empirical investigation of Indian process industries. Production planning & control, 29(2), pp. 158-169. [Google Scholar] [Crossref]

58. Pervin, N. & Mokhtar, M., 2022. The Interpretivist Research Paradigm: A Subjective Notion of a Social Context. International Journal of Academic Research in Progressive Education and Development , 11(2), pp. 419-428. [Google Scholar] [Crossref]

59. Preetpal, s. & Mahipal, s., 2023. Analysis of Barriers of Lean Approach Implementation in Manufacturing Industries. International Journal for Multidisciplinary Research (IJFMR), 5(4), pp. 1-16. [Google Scholar] [Crossref]

60. PSU, 2020. Lean Manufacturing, s.l.: Penn State University. [Google Scholar] [Crossref]

61. Saleem, G. & Leo, 2022. Impact of lean manufacturing on organizational performance through a moderating role of ERP. South Asian Management Review, 1(2), pp. 51-65. [Google Scholar] [Crossref]

62. Sarker, R. H. & Bhandari, P., 2024. Application of Lean Manufacturing in Developing Countries. Proceedings of the International Conference on Industrial Engineering and Operations Management , 1(1), pp. 24-34. [Google Scholar] [Crossref]

63. Saunders, M. N., Bristow, A., Lewis, P. & Thornhill, A., 2023. Research Methods for Business Students. 9th ed. Birmingham: Pearson. [Google Scholar] [Crossref]

64. Setiawan, I., Tumanggor, O. S. P. & Purba, H. H., 2021. Value Stream Mapping: Literature Review and Implications for Service Industry. Jurnal Sistem Teknik Industri , 23(2), pp. 1-12. [Google Scholar] [Crossref]

65. Shivangi, A. & Ashish, A., 2020. Uses, Advantages and Opportunities of Kanban methods in Mechanical Engineering and Product Manufacturing. International Journal of Scientific and Research Publications, 10(1), pp. 19-30. [Google Scholar] [Crossref]

66. Smith, T., 2021. Pragmatism. EBSCO, 1(1), pp. 1-10. [Google Scholar] [Crossref]

67. Statista, 2025. Hospitals - Nigeria. [Online] Available at: https://www.statista.com/outlook/hmo/hospitals/nigeria [Accessed 25 March 2025]. [Google Scholar] [Crossref]

68. Stock Analysis, 2025. Dangote Cement Plc (NGX:DANGCEM). [Online] Available at: https://stockanalysis.com/quote/ngx/DANGCEM/employees/ [Accessed 2 June 2025]. [Google Scholar] [Crossref]

69. Suroso, E. & Santosa, A. D., 2024. Effects Of Lean Manufacturing Practices On Operational. Journal of Research in Social Science And Humanities , 4(1), pp. 174-179. [Google Scholar] [Crossref]

70. Susanti, T., Rionaldi, R., Aristiawan, D. & Taufid, H., 2025. Implementation Of Just-In-Time (Jit) In Inventory Management: A Case Study In A Manufacturing Company. Eduvest - Journal Of Universal Studies, 5(7), pp. 6208-6216. [Google Scholar] [Crossref]

71. Taher, M. A. & Bashar, M. A., 2024. The impact of lean manufacturing concepts on industrial processes' efficiency and waste reduction. International Journal of Progressive Research in Engineering Management and Science, 4(6), pp. 338-349. [Google Scholar] [Crossref]

72. Touriki, F. E. et al., 2021. An integrated smart, green, resilient, and lean manufacturing framework: A literature review and future research directions. Journal of Cleaner Production, 319(15), pp. 1-20. [Google Scholar] [Crossref]

73. Vasileiou, K., Barnett, J., Thorpe, S. & Young, T., 2018. Characterizing and justifying sample size sufficiency in interview-based studies: systematic analysis of qualitative health research over a 15-year period. BMC Medical Research Methodology, 18(148), pp. 1-15. [Google Scholar] [Crossref]

74. Yan, W. & Yturralde, C., 2024. Lean Production Implementation and Challenges among SMEs in China: A Review. International Journal for Multidisciplinary Research (IJFMR), 6(5), pp. 1-13. [Google Scholar] [Crossref]

• The Impact of Ownership Structure on Dividend Payout Policy of Listed Plantation Companies in Sri Lanka
• Urban Sustainability in North-East India: A Study through the lens of NER-SDG index
• Performance Assessment of Predictive Forecasting Techniques for Enhancing Hospital Supply Chain Efficiency in Healthcare Logistics
• The Fractured Self in Julian Barnes' Postmodern Fiction: Identity Crisis and Deflation in Metroland and the Sense of an Ending
• Impact of Flood on the Employment, Labour Productivity and Migration of Agricultural Labour in North Bihar