ORIGINAL ARTICLE An integrated design methodology based on the use of group AHP-DEA approach for measuring lean tools efficiency with undesirable output Alireza Anvari & Norzima Zulkifli & Shahryar Sorooshian & Omid Boyerhassani Received: 17 December 2011 /Accepted: 27 September 2013 /Published online: 15 November 2013 # Springer-Verlag London 2013 Abstract The selection of lean tools is one of the crucial factors for decision makers and practitioners in a competitive environment. A few efforts have been made based on problem selection. Conversely, numerical studies have been done on analytical hierarchy process (AHP)–data envelopment analy- sis (DEA) as well as DEA-undesirable variables separately. Thus, there is a shortage of lean practitioners as well as the methods involved. The present research aims at integrating AHP and DEA with desirable and undesirable factors to evaluate the lean tools and techniques and to rank the aspect of efficacy. We suggest a logical procedure to measure the efficacy of lean tools on leanness and to prioritize them as decision makers. In this extensive research, we apply the integrated multicriteria decision-making approach, including the hybrid groups AHP and DEA models with desirable and undesirable variables, to assess the relative efficiency of lean manufacturing tools and techniques. Case studies are used to demonstrate the lean implementation in companies while being validated by a panel of experts. The integration of these approaches has created synergy and shown to be even more powerful. Thus, the proposed integrated AHP-DEA model can evaluate and rank different alternatives while considering desirable and undesirable variables in the production processes. Keywords Lean manufacturing . Lean tools selection . AHP . DEA . DMU's . Desirable and undesirable variables Nomenclature AHP Analytical hierarchy process BCC Banker–Charnes–Cooper CCR Charnes–Cooper–Rhodes CM Continuous process manufacturing CRS Constant returns to scale DEA Data envelopment analysis DM Discrete manufacturing DMU Decision-making units LM Lean manufacturing SMED Single-minute exchange of dies TPM Total productive maintenance TPS Toyota production system TQM Total quality management VRS Variable returns to scale VSM Value stream mapping 1 Introduction There has been a paradigm shift from craft to mass production and then lean manufacturing (LM) [1–3]. Mass production is specified with repetitive high volume with limited variety; meanwhile, LM is an integrated system with many tools and techniques, focused on waste elimination and value added, thus leading to cost reduction [4, 5]. Some of the most A. Anvari (*) Department of Industrial Engineering, Gachsaran Branch, Gachsaran, Iran e-mail: ar_anvar@yahoo.com N. Zulkifli Department of Mechanical and Manufacturing Engineering, UPM, Serdang, Malaysia e-mail: norzima@eng.upm.edu.my S. Sorooshian Department of Industrial Engineering, Science and Research Branch, Kerman, Iran e-mail: sorooshian@gmail.com O. Boyerhassani Department of Industrial Engineering, Najafabad Branch, Najafabad, Iran e-mail: omidboyer@gmail.com Int J Adv Manuf Technol (2014) 70:2169–2186 DOI 10.1007/s00170-013-5369-z