A benchmarking approach to lean quality practices: developing a strategic roadmap for port efficiency

Purpose This study demonstrates how lean tools and total quality management (TQM) methodologies can improve operational efficiency and competitiveness in port operations. Design/methodology/approach Data from three ports (United States, Costa Rica and Spain) were gathered via field observations, focus group discussions and interviews. Key processes analyzed were crane operations, yard management and gate inbound/outbound operations. Lean tools applied included fishbone analysis, value stream mapping (VSM), overall equipment effectiveness (OEE), DMAIC, bottleneck analysis, Kanban, 5S and quality function deployment (QFD). A benchmarking map was created to compare performance and guide lean implementation. Findings The US port achieved the highest level of operational efficiency through comprehensive lean tool adoption and training. Costa Rica excelled in yard operations but lagged elsewhere due to limited lean practice use. Spain actively used lean tools, but isolated application reduced their effectiveness. Research limitations/implications This study provides valuable insights into applying lean tools in port operations, but has notable limitations. It examined only three ports in different countries, each with unique regulatory and cultural contexts, limiting the generalizability of findings. The reliance on qualitative data offers rich detail but may introduce bias and lacks quantitative performance metrics. Confidentiality agreements also restricted disclosure of operational details, reducing comparative depth. Future research should expand the sample size to include more geographically and operationally diverse ports. Incorporating larger datasets and varied case studies would strengthen benchmarking frameworks. Practical implications This paper demonstrates how various lean tools help ports align with strategic objectives and foster continuous improvement. The benchmarking map provides a visual guide for implementing or refining lean practices. Originality/value This study provides practical insights into the application of lean and TQM tools in port environments and offers a structured benchmarking framework to support performance improvement across diverse operational contexts.