Addressing Production Constraints and Empowering Effective Knowledge Transfer Among Employees at XYZ Company: An Experience-Driven Framework

This study explores the interplay between production constraints and tacit knowledge transfer in a Made-to-Order (MTO) manufacturing context. It examines how these systemic operational inefficiencies and informal knowledge practices influence Lean maturity through the lens of the operational architecture of Lean principles, Value Stream Mapping (VSM), and SECI (Socialization, Externalization, Combination, Internalization). Evidence from extensive Focus Group Discussions with operational production employees and supervisors revealed that, despite a technically skilled workforce, formal Lean implementation is severely hampered by critical systemic administrative shortfalls, inconsistent digital interoperability across departmental silos, and a historically ingrained operational culture. These constraints often compel personnel to use localized “diskarte” (intuitive, culturally embedded workarounds) and informal "shadow systems" to ensure continuity of workflow where what could be achieved through systemic mechanisms is effortfully done manually, which further exacerbates delays in overall organizational velocity. As a result, although tacit knowledge serves as a primary stabilizer through informal mentoring, tribal knowledge sharing, and sensory learning, the study appears to identify hot spots where the "knowledge standard paradox" is particularly critical. Within this, heroics and brilliant ad hoc problem-solving save production times but, at best, hide deeper-level systemic structural failures from management. An Experience-Driven Framework is proposed to solve these vulnerabilities. It systematically integrates virtual supply chain modeling (VSM) with tactical tacit knowledge codification and strategic digital integration. Ultimately, it reveals why Lean maturity cannot be attained without institutionalizing operational resilience as a standardized, organizational system, rather than an erratic, person-dependent capability.