Development of Lean Six Sigma training module: evidence from an emerging economy

2019 ◽  
Vol 37 (5) ◽  
pp. 689-710
Author(s):  
Raja Sreedharan V. ◽  
Vijaya Sunder M. ◽  
Vandana Madhavan ◽  
Anand Gurumurthy
Keyword(s):  
Six Sigma ◽  
Manufacturing Sector ◽  
Practical Implication ◽  
Lean Six Sigma ◽  
Manufacturing Firms ◽  
Training Module ◽  
Online Questionnaire ◽  
Content Type ◽  
Single Standard ◽  
Periodic Evaluation

Purpose Nowadays, firms are keen on improving the quality culture in the organizations. The proven success of Lean and Six Sigma has given rise to the synergetic Lean Six Sigma (LSS) approach that has been catching fire in the past one decade. However, there exists a gap between the understanding and implementation of LSS in the organizations, especially in the emerging economies. Taking this as a valuable opportunity, the purpose of this paper is to present a development of LSS training module. Design/methodology/approach This study starts with a literature review of LSS to reinforce the understanding of the research subject in scope of manufacturing sector. Then, an online questionnaire was designed and used to collect responses from 181 companies located in the Indian sub-continent. Subsequently, the results obtained from the survey were analyzed using COARSE approach. Findings This study reveals two key findings and associated contributions. First, it was found that the overall awareness of LSS within the responded manufacturing firms is about 70.4 percent. Second, there is no single standard training module that exists in any of the sampled firms to cater to their quality programs. Hence, in order to improve the LSS awareness which could subsequently help managers as a resource for creating an efficient workplace, this paper presents a structured LSS training framework. Research limitations/implications Although this paper presents the importance of LSS and associated awareness level among the responded firms, more empirical evidence is required to generalize the model findings. Second, this study is scoped to firms that work out of the Indian sub-continent, and this provides a future opportunity to expand the scope of this research toward a global study for a comparison between emerging and developed economies. Third, this study is limited to manufacturing firms and hence paves an opportunity to research on a similar theme in services context as well. Practical implications Before embarking on an LSS journey, an organization can use the LSS training module proposed in this study to assess the employee awareness on LSS. Furthermore, organizations that already have a mature LSS practice can incorporate the LSS training module for periodic evaluation of the employees for effective change management. Originality/value The training module presented in this paper is the original contribution by the authors. This is no association to any single identifiable organization or associated funding. The direct practical implication of its application in real time is the value that managers could derive from the proposed LSS training framework.

scholarly journals Impact of perceived importance of cultural readiness factors on perceived importance of Lean Six Sigma success factors for manufacturers

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Alireza Shokri ◽  
Gendao Li
Keyword(s):  
Six Sigma ◽  
Success Factors ◽  
Manufacturing Sector ◽  
Lean Six Sigma ◽  
Manufacturing Firms ◽  
Content Type ◽  
Critical Success ◽  
Perceived Importance ◽  
The Impact

PurposeThis study aims at investigating the impact of the perceived importance of critical cultural readiness factors (CRFs) is on perceived importance of Lean Six Sigma (LSS) technical critical success factors (CSFs) in UK manufacturing sector.Design/methodology/approachA survey questionnaire through a multiple embedded case study was conducted. The study involves surveying people in the manufacturing firms followed by non-parametric Kruskal–Wallis test to study the relationships.FindingsIt was found that the people's perception towards impact of CRFs on technical CSFs of LSS projects is different depending upon each CRF, demographic factors and technical CSFs. This means that particular CRFs need to be prioritised to address LSS technical CSFs.Research limitations/implicationsThe study fills the research gap in investigating the perception of people towards inter-relationship of cultural or soft CSFs of LSS and technical or hard CSFs of LSS in manufacturing firms. Nevertheless, the authors suggest further multi-case study analysis covering different manufacturing fields as future studies.Practical implicationsThe study is crucial for managers financially to be ready to invest on a successful LSS project and it helps them to diagnose the cultural causes of failure in a more timely way and effectively.Originality/valueThis is a preliminary study focussing on analysing inter-relationship between perceived importance of soft readiness factors and perceived importance of implementing success factors as a missing jigsaw in the current literature.

Development of an integrated framework of LGSS strategies for Indian manufacturing firms to improve business performance: an empirical study

2020 ◽  
Vol 33 (1) ◽  
pp. 257-291 ◽  
Author(s):  
Lokpriya Gaikwad ◽  
Vivek Sunnapwar
Keyword(s):  
Six Sigma ◽  
Positive Impact ◽  
Manufacturing Sector ◽  
Manufacturing Firms ◽  
Manufacturing Industries ◽  
Environmental Benefits ◽  
Future Research ◽  
Continuous Growth ◽  
Content Type ◽  
Indian Industries

PurposeThis article aims to explore synergies between Lean, Green and Six Sigma practices in order to propose an integrated LGSS framework for continuous and incremental improvement in the Indian manufacturing industries. The three-dimensional LGSS framework seeks to provide various combinations and support operational, financial, environmental and social needs.Design/methodology/approachIn the research method, first, the current problems faced by Indian manufacturing industries are considered and proposition of a conceptual framework that qualitatively integrates synergistic aspects of Lean, Green and Six Sigma practices, and second, the framework is checked by a survey taken from 203 Indian firms by using SPSS-AMOS.FindingsThe hypothesized result suggests that the positive impact of integrated practices on firm performance in terms of operational, financial, social and environmental outcomes. It also provides a systemic and holistic approach to problem-solving through constant and incremental enhancement in the manufacturing sector.Research limitations/implicationsIn this research, only Indian manufacturing industries have been studied but can be extending into different geographical areas and sectors. Future research is also possible for different behavior and characteristics of companies that can lead to recommending strategies on how companies can improve performance. Most importantly, future research can try to understand which specific practice can contribute to competitive advantage and business success.Practical implicationsManufacturing firms that want to improve environmental sustainability should implement integrated LGSS practices into their supply chain. The set of combined practices improves operational, social, economical and environmental benefits.Social implicationsThe research presents an integrated approach of LSS for the manufacturing industry which leads their business processes to achieve economic sustainability through continuous growth and improved operational efficiency. Manufacturing industries result in outcomes like reduced cost, lead time, improved quality, sustainable market position, profitability, customer satisfaction, etc.Originality/valueThis research is different from previous studies because it integrates Lean, Green and Six Sigma practices into a unique framework that fulfills a specific need of the Indian manufacturing sector that guides operational, social, environmental and financial issues in Indian industries.

Modelling the barriers of Lean Six Sigma for Indian micro-small medium enterprises

2019 ◽  
Vol 31 (5) ◽  
pp. 673-695 ◽  
Author(s):  
Mahipal Singh ◽  
Pankaj Kumar ◽  
Rajeev Rathi
Keyword(s):  
Statistical Analysis ◽  
Six Sigma ◽  
Human Error ◽  
Practical Implication ◽  
Pairwise Comparison ◽  
Lean Six Sigma ◽  
Successful Implementation ◽  
Pairwise Comparison Matrix ◽  
Content Type ◽  
Small Medium Enterprises

Purpose The purpose of this paper is to investigate the barriers of Lean Six Sigma (LSS) and develop the interrelationship among them using interpretive structural modelling (ISM) and Matriced Impact Croises Multiplication Appliquee a un Classement (MICMAC). Design/methodology/approach Using systematic literature review and expert’s opinions, 26 LSS barriers have been extracted and finalized through statistical analysis, that is importance-index analysis and corrected item minus total correlation methods. The statistical analysis of purified 22 LSS barriers has been carried out and consistency of finalized barriers has been checked through reliability statistical test in Statistical Package for the Social Sciences software. Finally, the contextual relationship among finalized LSS barriers is developed using ISM and MICMAC approach. Findings The ISM model indicates that insufficient management commitment and involvement, lack of resources, lack of training and education, lack of strategic thinking, lack of training funds are strategic factors; improper project selection, poor selection of employee for belt training, lack of total employee involvement, lack of awareness of about LSS are prudent factors; unclear vision, high implementation cost, resistance to culture change, weak supplier linkage, poor alignment between company’s goal and customer demand are burst factors. Furthermore, MICMAC analysis is splitting the LSSBs in four clusters according to their driving power and dependency. These results provide a clear mind-set to engineering manager for focusing more on LSS barriers according to their driving power and dependency. Research limitations/implications There may be biasness in making pairwise comparison matrix of barriers due to involvement of expert’s opinion as human error. Practical implications The outcome of this paper provides robust practical implication for LSS researchers and practitioners. The researcher and practitioners must consciously concentrate on the identified LSSBs more conventionally during LSS implementation, and they need to plan strategically to avoid any implementation failure. Originality/value For successful implementation of LSS in any organization, it is necessary and permeable to make strategy for controlling LSS barriers at initial stage. So this paper is a leading attempt to highlight main LSS barriers and interrelate them using ISM and MICMAC approach. It provides a clear path for tackling LSS barriers to engineering managers, researchers and consultants.

Lean Six Sigma: a clinical treatment for the recovery of Indian manufacturing sector from the after-effects of coronavirus

2020 ◽  
Vol 17 (3) ◽  
pp. 311-322 ◽  
Author(s):  
Harsimran Singh Sodhi
Keyword(s):  
Six Sigma ◽  
Manufacturing Industry ◽  
Manufacturing Sector ◽  
Lean Six Sigma ◽  
Clinical Treatment ◽  
Content Type ◽  
After Effects ◽  
The World ◽  
Tools And Techniques ◽  
The Impact

PurposeManufacturing industry is quite badly hit due to the coronavirus. Manufacturing has been stopped in every country. The present study will provide assistance to the practitioners to recover manufacturing sector from the after-effects of coronavirus.Design/methodology/approachA thorough review of the recent articles published in the newspaper and web has been done to make a viewpoint on the global industrial impact due to epidemic corona. Reports of WHO, IMF, World Bank, RBI and so forth are also reviewed. Further, Lean Six Sigma has been suggested which can be implemented to recover manufacturing industry from the ill effects of corona.FindingsIn present study the problem causd in the manufacturing sector due to corona virus has been identified and a clinical treatment for the same has been proposed by using the tools and techniques of Lean Six Sigma.Originality/valueThe impact of coronavirus has become a huge issue not only for the physical health of human beings but also for the economic health of most of the countries in the world, as it is pushing the world economy toward huge economic depression. Therefore, it becomes the moral responsibility of industrial experts to suggest the tools and techniques to the manufacturing industry for faster recovery.

Implementing a Lean Six Sigma standardized toolset in a manufacturing company: a case study

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Nikolaos A. Panayiotou ◽  
Konstantinos E. Stergiou ◽  
Vassilis Chronopoulos
Keyword(s):  
Case Studies ◽  
Six Sigma ◽  
Success Factors ◽  
Manufacturing Sector ◽  
Lean Six Sigma ◽  
Small Scale ◽  
Manufacturing Companies ◽  
Content Type ◽  
Manufacturing Company

PurposeThe first purpose of this paper is the implementation of Lean Six Sigma (LSS) in a manufacturing company operating in South East Europe in order to understand the importance of critical success factors (CSFs) in LSS adoption and to find out the benefits that the company gained. The second purpose is to propose a standardized toolset based on DMAIC phases, for the application of LSS in small scale projects, in order to facilitate LSS adoption by more manufacturing companies.Design/methodology/approachThis case study is based on the interlacement of the Yin's method about case studies and the DMAIC method for the improved deployment of LSS.FindingsThe analysis of this case study shows that the company attained to benefit financially, operationally and organizationally from the implementation of LSS. The already existing mentality of CI inside the company helped the project procedure and the application of changes and improvements fulfilling LSS adoption CSFs.Practical implicationsThe paper constructs a toolset and studies the role of CSFs in order to achieve the desirable benefits in a manufacturing environment, constituting a guide for future LSS initiatives.Originality/valueAs stated by literature reviews, even though there are several papers concerning LSS implementation in the manufacturing sector, there is a need for more case studies papers, such as this one, in order to enrich the literature. In this paper, it is also the first time that a specific toolset for small scale projects is proposed based on to DMAIC which can be implemented in further LSS projects.

A comparative analysis of green-lean-six sigma enablers and environmental outcomes: a natural resource-based view

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Amna Farrukh ◽  
Sanjay Mathrani ◽  
Aymen Sajjad
Keyword(s):  
Natural Resource ◽  
Environmental Sustainability ◽  
Six Sigma ◽  
Energy Use ◽  
Pollution Prevention ◽  
Developing Nations ◽  
Lean Six Sigma ◽  
Manufacturing Firms ◽  
Resource Based View ◽  
Content Type

Purpose Despite differing strategies towards environmental sustainability in developed and developing nations, the manufacturing sector in these regional domains faces substantial environmental issues. The purpose of this study is to examine the green-lean-six sigma (GLSS) enablers and outcomes for enhancing environmental sustainability of manufacturing firms in both, a developed and developing country context by using an environment-centric natural resource-based view (NRBV). Design/methodology/approach First, a framework of GLSS enablers and outcomes aligned with the NRBV strategic capabilities is proposed through a systematic literature review. Second, this framework is used to empirically investigate the GLSS enablers and outcomes of manufacturing firms through in-depth interviews with lean six sigma and environmental consultants from New Zealand (NZ) and Pakistan (PK) (developed and developing nations). Findings Analysis from both regional domains highlights the use of GLSS enablers and outcomes under different NRBV capabilities of pollution prevention, product stewardship and sustainable development. A comparison reveals that NZ firms practice GLSS to comply with environmental regulatory requirements, avoid penalties and maintain their clean-green image. Conversely, Pakistani firms execute GLSS to reduce energy use, satisfy international customers and create a green image. Practical implications This paper provides new insights on GLSS for environmental sustainability which can assist industrial experts and academia for future strategies and research. Originality/value This is one of the early comparative studies that has used the NRBV to investigate GLSS enablers and outcomes in manufacturing firms for enhancing environmental performance comparing developed and developing nations

A conceptual Lean Six Sigma framework for quality excellence in higher education institutions

2018 ◽  
Vol 35 (4) ◽  
pp. 857-874 ◽  
Author(s):  
Vijaya Sunder M. ◽  
Jiju Antony
Keyword(s):  
Higher Education ◽  
Conceptual Framework ◽  
Six Sigma ◽  
Manufacturing Sector ◽  
Higher Education Institutions ◽  
Real Life ◽  
Lean Six Sigma ◽  
Content Type ◽  
Deployment Strategy ◽  
Life Context

Purpose The purpose of this paper is to present the potent application of Lean Six Sigma (LSS) in higher education services and to suggest a conceptual framework of deploying LSS in the higher education institutions (HEIs). Design/methodology/approach This paper aims to outline the importance of the quality excellence criterion in general through different constructs from the literature including TQM, Lean, Six Sigma and LSS. The paper further expands on the applicability of LSS in the HEI setting, with an understanding of HEI as comparatively different from the manufacturing sector from where LSS originated. The published literature on LSS and authors’ experience in the field of LSS (as practitioners) were used as sources for devising a conceptual framework for LSS deployment in HEIs. Findings The key finding from the study is the confirmation of LSS applicability in HEIs. The study also confirms that LSS is not anyone’s job but a key part of leadership agenda. The six-staged conceptual framework prescribed for the HEIs as part of the paper is the key contribution of this study. The model describes that LSS readiness is the foremost step in the LSS deployment journey in HEIs. The strategic perspectives of aligning the organisational vision for quality excellence need to be achieved by establishing a need for LSS through leadership. Then, developing an LSS deployment strategy becomes the next step. Educating the appropriate stakeholders (students) and team formation becomes the next important steps in the LSS deployment. Once the above steps are implemented in right way, identifying and implementing LSS projects becomes critical. The execution and closure of the LSS projects leads to quality excellence in HEIs. Research limitations/implications Since the framework prescribed here is a conceptual framework, it deserved a testing in the real-life context. This leaves an opportunity for future researchers to test and expand on the implications of the model. Though the LSS framework is customised for HEIs, the fundamental factors essential for any change management initiative holds correct for LSS as well, and hence these are not elaborated as part of this paper. Originality/value This paper would serve as an excellent resource for both academicians and LSS practitioners in HEIs, for deployment. The framework presented here is the original work contributed by the authors, as the first of its kind in the academic literature relevant to LSS in HEIs.

A systematic review of Lean Six Sigma for the manufacturing industry

2015 ◽  
Vol 21 (3) ◽  
pp. 665-691 ◽  
Author(s):  
Saja Ahmed Albliwi ◽  
Jiju Antony ◽  
Sarina Abdul halim Lim
Keyword(s):  
Current Literature ◽  
Six Sigma ◽  
Manufacturing Industry ◽  
Manufacturing Sector ◽  
Implementation Process ◽  
Lean Six Sigma ◽  
Future Research ◽  
Content Type ◽  
Motivation Factors ◽  
Practical Implications

Purpose – The purpose of this paper is to explore the most common themes within Lean Six Sigma (LSS) in the manufacturing sector, and to identify any gaps in those themes that may be preventing users from getting the most benefit from their LSS strategy. This paper also identifies the gaps in current literature and develops an agenda for future research into LSS themes. Design/methodology/approach – The following research is based on a review of 37 papers that were published on LSS in the top journals in the field and other specialist journals, from 2000 to 2013. Findings – Many issues have emerged in this paper and important themes have cited which are: benefits, motivation factors, limitations and impeding factors. The analysis of 19 case studies in the manufacturing sector has resulted in significant benefits cited in this paper. However, many gaps and limitations need to be explored in future research as there have been little written on LSS as a holistic strategy for business improvement. Practical implications – It is important for practitioners to be aware of LSS benefits, limitations and impeding factors before starting the LSS implementation process. Hence, this paper could provide valuable insights to practitioners. Originality/value – This paper is based on a comprehensive literature review which gives an opportunity to LSS researchers to understand some common themes within LSS in depth. In addition, highlighting many gaps in the current literature and developing an agenda for future research, will save time and effort for readers looking to research topics within LSS.

scholarly journals Scoping review of the readiness for sustainable implementation of Lean Six Sigma projects in the manufacturing sector

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Alireza Shokri ◽  
Jiju Antony ◽  
Jose Arturo Garza-Reyes ◽  
Michelle Upton
Keyword(s):  
Scoping Review ◽  
Six Sigma ◽  
Manufacturing Sector ◽  
Green Manufacturing ◽  
Lean Six Sigma ◽  
Content Type ◽  
Sustainable Implementation ◽  
Step Model ◽  
State Of Research ◽  
Traditional Approaches

PurposeThis work presents a synthesis of current literature published from 2010 to provide an overall understanding of the sustainable implementation of Lean Six Sigma (LSS) projects in terms of project approaches rather than outcomes.Design/methodology/approachA comprehensive and validated ten-step model was applied to conduct a scoping review with the following three broad phases: “review planning”, “review execution” and “review reporting”.FindingsThe analysis shows that while a few geographically and methodologically broad research studies have been conducted on LSS and green manufacturing integration, no studies have examined organisational culture or conducted readiness assessments on the sustainable implementation of LSS projects in the manufacturing sector.Research limitations/implicationsThe present study contributes to existing knowledge by describing the current state of research on green LSS integration. The study also identifies a lack of research on the deployment of sustainable LSS projects for manufacturers. Further empirical analyses that include case studies must be conducted to assess the negative environmental impacts of LSS projects.Originality/valueThis study serves as an initial call for practitioners and research scholars to favour the sustainable deployment of LSS projects in manufacturing alongside the use of traditional approaches with a focus on costs, quality and delivery.

scholarly journals Green implementation of Lean Six Sigma projects in the manufacturing sector

2020 ◽  
Vol 11 (4) ◽  
pp. 711-729 ◽  
Author(s):  
Alireza Shokri ◽  
Gendao Li
Keyword(s):  
Environmental Impact ◽  
Environmental Sustainability ◽  
Six Sigma ◽  
Manufacturing Sector ◽  
Emerging Market ◽  
Lean Six Sigma ◽  
Process Efficiency ◽  
Production Volume ◽  
Traditional Values ◽  
Content Type

Purpose Historically, Lean Six Sigma (LSS) implementation has demonstrated a great deal of enhancement to process efficiency, profitability and customer satisfaction. The emerging market pressure for developing better quality, cheaper and greener products invokes a change of view in LSS economical effectiveness. The purpose of this study is to identify under which condition the final output of LSS projects with traditional strategic benefits are more environmentally friendly. Design/methodology/approach To investigate the choice of different types of LSS projects, the environmental impact under different conditions and the comparison of those conditions, the author developed an analytical mathematical model and analysed four different propositions. Findings The final price and production volume were recommended as mediating factors to leverage an LSS project to achieve a greener, customised and finance-oriented outputs. Research limitations/implications This research contributes to existing LSS research and knowledge development via promoting the different perspectives of LSS and environmental sustainability integration. Practical implications This study further enables managers to identify the cut-off point in relation to the production volume and finished prices to leverage the expected financial outputs and environmental impact of the LSS project. This would potentially promote a green LSS project in both implementation and output, alongside its traditional values. Originality/value This study uses a modelling approach to identify the conditions under which the actual methodology of the LSS project could be green via less energy consumption with consideration of expected LSS values and outcomes.

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