Development of a Survey Combining Lean, Quality, Safety and Culture in Manufacturing

Industrial systems such as lean practices, quality systems, workplace safety, and organisational culture are often managed as separate systems; however, in practice, they are interdependent. This study presents a preliminary survey instrument (CiE II) to assess organisational conditions commonly associated with effectiveness in manufacturing systems. A multi-stage refinement process was applied to an initial 107-item survey using pilot data (n = 127) collected from engineering students with work-integrated industry experience. The methodology combined exploratory factor analysis, item response theory, and thematic analysis to improve both statistical and conceptual coherence. The resulting instrument comprised 28 items, making it more suitable for industrial deployment. Analysis of responses (N = 127) identified three common facets that support lean, quality, safety, and culture. These are (i) Integrated Quality and Workflow Management (α = 0.960), referring to workers perceptions that quality standards exist and that they are resourced to meet them; (ii) Safe and Collaborative Work Culture (α = 0.901), referring to perceptions of behavioural norms and that workers will be treated fairly within the team; (iii) Supportive Leadership and Professional Growth (α = 0.852), referring to perceptions that management supports workers’ ongoing professional development. The potential benefit is the provision of a candidate survey that economically covers four key domains of relevance for manufacturing organisations. This has the potential to allow cross-domain correlations and larger-span regression models that integrate the four domains.