The role of transformational leadership in the sustainable implementation of operational excellence in manufacturing

Abstract

This study explored the role of transformational leadership in the sustainable implementation of operational excellence within manufacturing organisations in KwaZulu-Natal, South Africa. Although operational excellence systems and practices such as Total Quality Management, Lean, and continuous improvement are widely adopted (Tavana et al., 2020), many firms continue to experience difficulty sustaining performance gains over time, particularly when leadership attention shifts or organisational pressures intensify (Sony, 2019). Anchored in transformational leadership theory and supported by the dynamic capabilities framework, the research investigated how leadership behaviours contributed to embedding operational excellence as an enduring organisational capability as opposed to a short-term initiative. A qualitative, interpretivist research design was employed, using semi-structured interviews with heads of departments and middle managers in operational excellence across diverse manufacturing subsectors. The dataset was examined using an inductive approach guided by Braun and Clarke’s six-phase thematic analysis framework. (Braun & Clarke, 2006; Byrne, 2021), supported by ATLAS.ti.25 software. The findings indicated that transformational leadership sustained operational excellence through practices of visibility, coaching, empowerment, and long-term consistency, which fostered trust, psychological safety, and employee ownership of improvement routines. Sustainability was further strengthened when leadership influence was institutionalised through governance mechanisms such as standard work, audit cycles, KPI cascades, and digital performance visibility. The study contributed to scholarship by clarifying governance and institutionalisation as key mediating mechanisms linking transformational leadership to sustained continuous improvement. Practically, it provided actionable guidance for manufacturing leaders seeking resilient, self-reinforcing operational excellence systems in emerging-market contexts.