Lean Six Sigma education in manufacturing companies: the case of transitioning markets

Kybernetes ◽  
2016 ◽  
Vol 45 (9) ◽  
pp. 1421-1436 ◽  
Author(s):  
Klemen Kavčič ◽  
Dušan Gošnik
Keyword(s):  
Six Sigma ◽  
Global Economy ◽  
Organizational Factors ◽  
Transition Countries ◽  
Lean Six Sigma ◽  
Project Managers ◽  
Management Tool ◽  
Manufacturing Companies ◽  
Content Type ◽  
East European

Purpose In the global economy, managers are constantly innovating with their use of available Lean Six Sigma (LSS) tools. Some factors, such as training and the right educational goals, have gained strong global acceptance. The purpose of this paper is to focus on contributions to organizational factors that predict organizations usage of LSS management tools to investigate expectations of project managers prior to LSS education and the extent of fulfilment of those expectations following LSS education in Slovenia, an East European country. Design/methodology/approach This research provides an empirical analysis of LSS as a learning structure and the characteristics of LSS project managers, followed by the results of an analysis of LSS usage in manufacturing companies in Slovenia following comparative surveys carried out in 2008 and 2013. Findings The top four essential characteristics for LSS organizations in 2013 include: being an innovative LSS project manager; being an effective communicator; having networking ability; and being a positive thinker. Results from 2008 to 2013 have shown differences in the stages of LSS implementation in Slovenia in these years. Differences were also seen in the level of participants’ LSS training in the studies performed. Originality/value This paper presents the first ever comparison study regarding the status of LSS education in transition countries, such as in Slovenian manufacturing companies. The study shows the expectations of participants before LSS education and their fulfilment following it. The research is original in many aspects: it includes aspects of external and internal LSS training in companies, it focusses on the manufacturing companies in the transition country of Slovenia and it provides a comparison of results in 2008 and in 2013 and an overview of the progress of LSS education. The paper will be of great value to academics, consultants, researchers, practitioners of LSS, current and future management and owners of companies in Slovenia and other similar East European transition countries. The findings will be useful in business practice for understanding the influences of education and training factors on LSS management tool usage.

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 new framework to support Lean Six Sigma deployment in SMEs

2019 ◽  
Vol 10 (1) ◽  
pp. 58-80 ◽  
Author(s):  
Carlos Abraham Moya ◽  
Daniel Galvez ◽  
Laurent Muller ◽  
Mauricio Camargo
Keyword(s):  
Case Studies ◽  
Six Sigma ◽  
Success Factors ◽  
Performance Indicator ◽  
Lean Six Sigma ◽  
Organizational Capabilities ◽  
Successful Implementation ◽  
Manufacturing Companies ◽  
Content Type ◽  
Readiness Level

Purpose The purpose of this paper is to propose an assessment approach to evaluate the organizational capabilities to deploy a Lean Six Sigma (LSS) strategy. Design/methodology/approach Based on a comprehensive literature review, critical success factors required to deploy LSS were defined. These key factors are evaluated by a questionnaire based on maturity grids and structured as a multi-criteria model to compute a potential LSS performance indicator. This approach is illustrated through two case studies. Findings To promote a successful implementation of LSS in SMEs, it is necessary to consider five main critical factors. The evaluation of these factors could be achieved thanks to a multi-criterion-based maturity indicator for the LSS implementation. The case studies show that this approach allows SMEs to understand their strengths and weaknesses and thus better prepare the implementation of LSS. Research limitations/implications The proposed tool identifies characteristics of companies leading to successful LSS implementation; but is not yet able to provide a detailed strategy to improve them. The case studies were applied to manufacturing companies; therefore, there is no evidence of conclusions in the context of services. Practical implications The proposed methodology will help managers and practitioners to evaluate the readiness level of a company to implement LSS. Then, they could estimate the effort required to achieve the LSS deployment. Originality/value This paper proposes a new metric of the capacity to implement the LSS successfully in SMEs: the Lean Six Sigma Global Index. This indicator is based on a survey completed by managers and supported by observable phenomena to establish a tailored diagnosis before the LSS implementation.

Assessing the adoption of critical success factors for lean six sigma implementation

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Carlos Gastelum-Acosta ◽  
Jorge Limon-Romero ◽  
Diego Tlapa ◽  
Yolanda Baez-Lopez ◽  
Guilherme Tortorella ◽  
...  
Keyword(s):  
Six Sigma ◽  
Critical Success Factors ◽  
Success Factors ◽  
The United States ◽  
Lean Six Sigma ◽  
Extensive Literature ◽  
Manufacturing Companies ◽  
Cross Sectional ◽  
Content Type ◽  
Critical Success

PurposeThe objective of the study is to design and validate an instrument that allows organizations to assess their status regarding the adoption of the critical success factors (CSFs) that enable lean six sigma (LSS) implementation in order to achieve the expected benefits.Design/methodology/approachAn extensive literature review was conducted to define the LSS CSFs that have to be considered for the development of the questionnaire that would later be applied across all manufacturing companies on the Northern Mexican border. Once the database was built, a statistical verification of the assumptions required for factor analysis took place. Finally, the due construct validation was carried out to verify whether the proposed instrument measured reliably what it is intended to.FindingsA questionnaire measuring nine CSFs, as well as the benefits associated with the implementation of LSS, was designed and validated through 61 items.Research limitations/implicationsThe main limitations of this study are that the research is cross-sectional and that the study was carried out taking as a reference only exporting manufacturing companies located in the border area between Mexico and the United States.Practical implicationsThe validated instrument is expected to serve as a useful tool for companies interested in the implementation of LSS.Originality/valueThis study introduces a validated tool for the analysis of LSS CSFs while providing evidence of construct validity and the solid structure of the factors.

Lean six sigma project management – a stakeholder management perspective

2016 ◽  
Vol 28 (1) ◽  
pp. 132-150 ◽  
Author(s):  
Vijaya Sunder M.
Keyword(s):  
Project Management ◽  
Six Sigma ◽  
Financial Services ◽  
Stakeholder Management ◽  
Phase 1 ◽  
Lean Six Sigma ◽  
Project Managers ◽  
Service Industries ◽  
Content Type ◽  
Proposed Model

Purpose – The purpose of this paper is to understand the success of Lean Six Sigma (LSS) in banking and financial services industry and to develop a structured stakeholders management model for successful LSS project management. Design/methodology/approach – A two-phase methodology is used. Phase 1 establishes the literature to understand two key process improvement methodologies – Lean and Six Sigma and to derive synergies by their combination leading to success in banking and financial services. The literature also helps to recognize the importance of stakeholder management in LSS projects and to understand how it helps in accelerating change in organizations. Phase 2 of the methodology is based on the interviews conducted by 56 global LSS project managers. This is to understand the practical challenges faced by the LSS project managers in banking and financial services tying back to the existing literature. Findings – The paper identifies the possible opportunities for structured stakeholder management across different phases of Define-Measure-Analyze-Improve-Control (DMAIC) project flow. The first of this kind, “Inform-Involve-Influence” model has been developed based on the understanding from literature and conclusions from the interviews conducted. The proposed model highlights the different set of stakeholders involved in LSS projects and their role in the project. The model also helps categorizing the stakeholders based on the DMAIC phases. Research limitations/implications – The paper is limited to readymade use in banking and financial service environments for LSS projects. However the paper sets a platform for further research to customize the proposed model for other service industries. Practical implications – The model proposed as part of the paper helps project managers to inform, involve and influence different set of stakeholders at different phases of the DMAIC flow. The model leaves an opportunity for further research and customization for other service industries outside the banking and financial services space like hospitality, government, heath care, etc. Benefits and limitations of the model were presented as part of the paper. Originality/value – The paper is the original work contributed by the author. Both the survey findings and the model developed are author’s original contribution for both academicians and corporate professionals.

An exploration of the extent of Lean Six Sigma implementation in the West of Ireland

2018 ◽  
Vol 9 (3) ◽  
pp. 444-462 ◽  
Author(s):  
Richard Iyede ◽  
Enda Francis Fallon ◽  
Pat Donnellan
Keyword(s):  
Six Sigma ◽  
Success Factors ◽  
Lean Six Sigma ◽  
Top Management ◽  
Management Support ◽  
Manufacturing Companies ◽  
The West ◽  
Content Type ◽  
Failure Factors ◽  
West Of Ireland

PurposeThe purpose of this paper is to explore the extent of Lean Six Sigma (LSS) implementation within manufacturing companies in the West of Ireland. It examines the key success and failure factors, benefits and quality tools influencing LSS projects deployment.Design/methodology/approachThe study adopted a mixed research method (quantitative and qualitative approach). Research data were collected through a structured survey questionnaire to the target population followed by interview case studies with four manufacturing companies to gather additional insight. The targeted respondents were manufacturing engineers, quality engineers, process improvement managers, operations managers, R&D engineers, LSS experts and validation engineers.FindingsLSS initiatives are still relatively unknown to many SMEs organisations, whereas large companies have adopted LSS for some time. Top management commitment, understanding the LSS methodology, tools and techniques, integrating LSS to business strategy, organisational cultural change and training and education were the topmost key success factors. Organisational strategy, lack of top management support, expensive cost for LSS projects, unclear prioritisation of LSS projects and cost effectiveness were the most important failure factors influencing LSS implementation.Originality/valueThis research is the original work provided by the author and is expected to address the shortcomings of both SMEs and large organisations in the West of Ireland. The recommendations and frameworks reported in this paper can be used by manufacturing and service companies in Ireland for efficiency, competitiveness and continuous improvement.

scholarly journals A study into the reasons for process improvement project failures: results from a pilot survey

2019 ◽  
Vol 36 (10) ◽  
pp. 1699-1720 ◽  
Author(s):  
Jiju Antony ◽  
Fabiane Letícia Lizarelli ◽  
Marcelo Machado Fernandes ◽  
Mary Dempsey ◽  
Attracta Brennan ◽  
...  
Keyword(s):  
Process Improvement ◽  
Six Sigma ◽  
Lean Six Sigma ◽  
Successful Implementation ◽  
Manufacturing Companies ◽  
Improvement Project ◽  
Content Type ◽  
Pilot Survey ◽  
Project Failures ◽  
The Impact

Purpose Process improvement initiatives, such as Lean, Six Sigma and Lean Six Sigma, typically have common characteristics that are carried through projects. Whilst a project’s performance is an important determinant of the successful implementation of continuous improvement (CI) initiatives, its failure can undermine the impact of any CI initiative on business performance. As a result, an understanding of the reasons of process improvement project failures is crucial. The purpose of this paper is to present the results of a pilot survey highlighting the most common reasons for process improvement project failures. Design/methodology/approach This paper presents a pilot survey of 42 Brazilian manufacturing specialists who have been involved in process improvement projects. The participants of this survey were Six Sigma Master Black Belts, Black Belts, Green Belts and Six Sigma champions from manufacturing companies in Brazil. The survey questionnaire was piloted with five experts in the field in order to ensure that the questions were valid and technically sound. Findings The execution of Six Sigma projects in organizations results in a moderate rate of project failures. These failures can cost organizations several millions of dollars especially within the context of larger organizations. The main reasons for project failure, as cited by the specialists include: resistance to change, lack of commitment and support from top management and incompetent teams. Research limitations/implications The authors report the findings from a pilot survey having a limited sample size. Moreover, the data have been collected from one country and primarily from large manufacturing companies. Originality/value To the best of the authors’ knowledge, this is the first empirical study looking into the reasons for process improvement project failures. The authors argue that if the top reasons for such failures are understood, a framework can be developed in the future that can mitigate the chance of project failures during project execution. This could potentially lead to significant savings to the bottom-line of many organizations.

scholarly journals Knowledge-based Lean Six Sigma maintenance system for sustainable buildings

2017 ◽  
Vol 8 (1) ◽  
pp. 109-130 ◽  
Author(s):  
Jasim Aldairi ◽  
M.K. Khan ◽  
J. Eduardo Munive-Hernandez
Keyword(s):  
Conceptual Framework ◽  
Six Sigma ◽  
Research Work ◽  
Lean Six Sigma ◽  
Rule Base ◽  
Sustainable Buildings ◽  
Sustainable Building ◽  
Content Type ◽  
Environmentally Sustainable ◽  
Knowledge Based

Purpose This paper aims to develop a knowledge-based (KB) system for Lean Six Sigma (LSS) maintenance in environmentally sustainable buildings (Lean6-SBM). Design/methodology/approach The Lean6-SBM conceptual framework has been developed using the rule base approach of KB system and joint integration with gauge absence prerequisites (GAP) technique. A comprehensive literature review is given for the main pillars of the framework with a typical output of GAP analysis. Findings Implementation of LSS in the sustainable building maintenance context requires a pre-assessment of the organisation’s capabilities. A conceptual framework with a design structure is proposed to tackle this issue with the provision of an enhancing strategic and operational decision-making hierarchy. Research limitations/implications Future research work might consider validating this framework in other type of industries. Practical implications Maintenance activities in environmentally sustainable buildings must take prodigious standards into consideration, and, therefore, a robust quality assurance measure has to be integrated. Originality/value The significance of this research is to present a novel use of hybrid KB/GAP methodologies to develop a Lean6-SBM system. The originality and novelty of this approach will assist in identifying quality perspectives while implementing different maintenance strategies in the sustainable building context.

From IMS and six sigma toward TQM: an empirical study from Serbia

2015 ◽  
Vol 27 (3) ◽  
pp. 341-355 ◽  
Author(s):  
Vidosav Majstorovic ◽  
Tatjana V. Sibalija
Keyword(s):  
Quality Management ◽  
Six Sigma ◽  
Management Practice ◽  
Current Status ◽  
Quality Engineering ◽  
Manufacturing Companies ◽  
Total Quality ◽  
Content Type ◽  
Dmaic Method ◽  
Comprehensive Study

Purpose – The purpose of this paper is to present the current status of a quality management practice in Serbia, in terms of the development and application of integrated managements systems (IMS), and research and implementation of Six Sigma and the related techniques. Design/methodology/approach – Two main aspects of total quality management (TQM) have been considered: institutional (organisational or strategic) aspect that corresponds to standardised management systems and their integration, and technical (quality engineering) aspect whose main contributor is Six Sigma. The findings of a comprehensive study on IMS implementation in Serbia have been presented, based on the results of a questionnaire that was sent to 54 organisations during 2013. Also, the significant technical improvements and tangible benefits of a recently conducted Six Sigma project were shown, including the application of the advanced quality engineering techniques within DMAIC method. Findings – Good QM practice in Serbia is improving, both in terms of the organisational (IMS) and technical (Six Sigma) aspect, that server as a good basis for the adoption of TQM in manufacturing companies from various sectors. It could be anticipated that these results will facilitate the adoption of an overall TQM culture in Serbia and leverage its future sustainability. Originality/value – This paper offers key insights into IMS and Six Sigma implementation in Serbia. This could encourage manufacturing organisations in developing countries to adopt IMS and Six Sigma, in order to boost the overall TQM culture and gain a competitive advantage.

Critical success factors of Lean Six Sigma deployment: a current review

2015 ◽  
Vol 6 (4) ◽  
pp. 339-348 ◽  
Author(s):  
Fairul Anwar Abu Bakar ◽  
Khairanum Subari ◽  
Mohd Amran Mohd Daril
Keyword(s):  
Six Sigma ◽  
Critical Success Factors ◽  
Success Factors ◽  
Lean Six Sigma ◽  
Success Story ◽  
Content Type ◽  
Critical Success ◽  
Improvement Methodologies ◽  
Practical Implications ◽  
A Current

Purpose – The purpose of this paper is to review and gather the latest critical success factors (CSF) of Lean Six Sigma (LSS) deployment and implementation into a comprehensive list of factors. Design/methodology/approach – The approach taken by authors in this study was to analyze the latest literature review starting 2010 onwards and focus on CSFs of LSS (not dedicated as Lean or Six Sigma) by excluding other improvement methodologies or initiatives, e.g. Lean, Six Sigma, TQM, TRIZ etc. Findings – Five significant CSFs were identified (initially 97 CSFs listed from 13 papers) out of nine groups/headers listed in clustering analysis using Affinity Diagram tool and new headers mapping. Practical implications – Most of the organisations were aware of the success story on LSS, but did not scrutinize or consider its CSFs. By knowing the outcome of this paper, it can help open eyes regarding readiness before implementing LSS. Originality/value – At the end of this paper, the authors tried to cluster the CSFs similarities that could intentionally provide the guidelines and references to industries/companies for successful deployment and implementation of LSS in future endeavours.

The application of Lean Six Sigma and supply chain resilience in maritime industry during the era of COVID-19

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Yugowati Praharsi ◽  
Mohammad Abu Jami’in ◽  
Gaguk Suhardjito ◽  
Hui Ming Wee
Keyword(s):  
Supply Chain ◽  
Continuous Improvement ◽  
Six Sigma ◽  
Business Processes ◽  
Lean Six Sigma ◽  
Maritime Industry ◽  
Content Type ◽  
Supply Chain Resilience ◽  
Control Approach ◽  
Logistics Services

Purpose This study aims to apply a Lean Six Sigma framework to support continuous improvement in the maritime industry (shipbuilding, logistics services and shipping companies) during COVID-19 pandemics. By applying the concepts of Lean Six Sigma and supply chain resilience, the most suitable continuous improvement method for the maritime industry is developed to maintain a resilient supply chain during COVID-19. Design/methodology/approach A specific shipbuilding, logistics services and shipping company in Indonesia is chosen as the research object. The Lean Six Sigma framework reveals the wastes through the supply chain resilience concept, and implements internal business processes to maintain optimal system performance. Findings The paper identifies important implementation aspects in applying Lean Six Sigma to shipbuilding, logistics services and shipping. The DMAIC (define, measure, analyze, improve and control) approach is applied to achieve supply chain resilience. Resilient measures are generated for the case companies to maximize performance during the pandemics. Practical implications This paper provides a new insight for integrating Lean Six Sigma and resilience strategies in the maritime industry during COVID-19 disruptions. The authors provide some insights to sustain the performance of the maritime industries under study. Originality/value This study is part of the first research in the maritime industry that focuses on continuous improvement during COVID-19 using Lean Six Sigma and supply chain resilience.

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