An investigation and implementation framework of Lean Green and Six Sigma (LG&SS) strategies for the manufacturing industry in India

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Jaivesh Gandhi ◽  
Shashank Thanki ◽  
Jitesh J. Thakkar
Keyword(s):  
Six Sigma ◽  
Manufacturing Industry ◽  
Manufacturing Sector ◽  
Sustainable Growth ◽  
Manufacturing Industries ◽  
Successful Implementation ◽  
Implementation Framework ◽  
Content Type ◽  
Micmac Analysis ◽  
Fuzzy Micmac

PurposeThe Indian manufacturing sector currently contributes 16–17% to gross domestic product (GDP) and gives employment to around 12% (2014) of the country's workforce. Among the various initiatives planned under Atma Nirbhar Bharat and “Make in India”, the Indian government aims to increase the share of the manufacturing sector to country's GDP to 25% by 2025. To ensure sustainable growth of the Indian manufacturing industries in global market, successful and implementation of strategies such as lean manufacturing, green manufacturing along with six sigma are crucial. This research aims at identification and analysis of barriers to successful implementation of integrated Lean Green Six Sigma (LG&SS) strategies.Design/methodology/approachBased on an evaluative literature review and expert's opinion, this research identifies 18 barriers to lean, green and six sigma implementation in the manufacturing industry in India. The inter-relationships among the barriers is identified using an integrated approach of ISM (interpretive structural modelling) and Fuzzy Matrice d’Impacts Croisés Multiplication Appliquée á un Classement (MICMAC).FindingsISM helps to derive key managerial insights and implementation plan based on the identified inter-relationships among the barriers. Fuzzy MICMAC analysis classifies the barriers into four categories, namely, autonomous, driver, dependent and linkage to understand their relative impact on the implementation of LG&SS practices in the Indian manufacturing industry. “Lack of cooperation and mutual trust between management and employees”, “The scarcity of time and work pressure”, “lack of continuous improvement work culture” and “lack of cooperation from suppliers” that forms the top most level of the model. “Weak legislation” is a highly significant barrier to LG&SS implementation in the Indian manufacturing industries.Practical implicationsIt is expected that the findings of this research will help the Indian manufacturing industry to derive a sustainable competitive advantage through an effective implementation of LG&SS practices.Originality/valueThis study can be seen as the first attempt in investigating barriers to successful implementation of lean, green and six sigma strategies in the Indian manufacturing industries using ISM and fuzzy MICMAC analysis.

Sustainability assessment in the manufacturing industry: a review of recent studies

2018 ◽  
Vol 25 (8) ◽  
pp. 3162-3179 ◽  
Author(s):  
Shamraiz Ahmad ◽  
Kuan Yew Wong
Keyword(s):  
Manufacturing Industry ◽  
Sustainability Assessment ◽  
Manufacturing Sector ◽  
Social Indicators ◽  
Sustainable Manufacturing ◽  
Manufacturing Industries ◽  
Bottom Line ◽  
Content Type ◽  
The Status ◽  
Different Levels

Purpose The purpose of this paper is to review and analyze the recent sustainability assessment studies in the manufacturing industry from the triple-bottom-line (TBL) perspective. This paper aims to depict the status quo of practical sustainability assessment, summarize the different levels and boundaries of evaluation, and highlight the difficulties and further improvements needed to make the assessment more effective in the manufacturing industry. Design/methodology/approach Four keywords, namely, sustainability assessment, sustainable manufacturing, TBL and green production, were used to explore and find the relevant articles. First, this paper systematically reviewed the studies and analyzed the different levels and boundaries of sustainability assessment. Following this, the reviewed studies were critically discussed along with their merits and shortcomings. Findings The review showed that most of the sustainability assessment studies were conducted on product, company and process levels in the manufacturing industry. Nevertheless, there is still a need to focus more on plant and process level assessments to achieve the TBL objectives. Environmental assessment is comparatively matured in manufacturing industries. However, from the economic and social viewpoints, only cost analysis and workers’ safety, respectively, were considered in most of the studies. The economic and social indicators need to be more inclusive and should be validated and standardized for manufacturing industries. Originality/value Unlike previous sustainability assessment reviews in manufacturing industries which were mostly based on life cycle assessment, this paper has included environmental, social and economic aspects in one comprehensive review and focused on recent studies published from 2010 to 2017. This paper has explored the recent sustainability assessment trends and provided insights into the development of sustainability assessment in the manufacturing sector.

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.

An investigation into manufacturing performance achievements accrued by Indian manufacturing organization through strategic 5S practices

2018 ◽  
Vol 67 (4) ◽  
pp. 754-787 ◽  
Author(s):  
Jugraj Singh Randhawa ◽  
Inderpreet Singh Ahuja
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Service Industry ◽  
Manufacturing Sector ◽  
Successful Implementation ◽  
Automotive Manufacturing ◽  
Content Type ◽  
Manufacturing Performance ◽  
Improvement Programs ◽  
Manufacturing Organization

Purpose The purpose of this paper is to evaluate the quantitative and qualitative benefits accrued by an Indian automotive parts industry through strategic 5S implementation initiatives. Design/methodology/approach The study involves evaluation of steps involved in systematic implementation of 5S program methodology in an automotive manufacturing organization and investigation of achievements accrued by the industry through the successful implementation of 5S program. Findings The empirical results of the study have revealed that effective practice of 5S program brings considerable level of improvements in the quality, production, cost optimizations, employee’s morale values and work culture in the manufacturing industry. The industry accrued both tangible and non-tangible benefits through the holistic adoption of 5S principals. 5S principals have been envisioned to further support other quality improvement programs like lean manufacturing initiatives of the organizations. Research limitations/implications The limitation of the study is that this research has been carried out in only manufacturing industry while similar study will be conducted in the service industry also. Originality/value Global competition in the manufacturing sector has provided necessary impetus for manufacturing organizations for affecting continuous improvements in manufacturing performance for achieving sustainability and profitability in the competitive market. 5S implementation is the fundamental tool for the overall achievements in both quantitative and qualitative performance enhancements in the manufacturing as well as service organizations.

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.

Critical review and analysis of measuring the success of Six Sigma implementation in manufacturing sector

2018 ◽  
Vol 35 (8) ◽  
pp. 1519-1545 ◽  
Author(s):  
Mihir Patel ◽  
Darshak Arunbhai Desai
Keyword(s):  
Performance Indicators ◽  
Critical Review ◽  
Six Sigma ◽  
Manufacturing Sector ◽  
Service Industries ◽  
Manufacturing Industries ◽  
Content Type ◽  
Process Indicators ◽  
Six Sigma Methodology ◽  
And Performance

Purpose The purpose of this paper is to capture the status of implementation of Six Sigma in various manufacturing industries and also examine the success of the Six Sigma by using different performance indicators. Design/methodology/approach The methodology of critical review involves the selection and classification of 112 research articles on the implementation of Six Sigma in different manufacturing industries. The selected articles are categorized by the following: articles distribution based on the year of publication, publication database, various journals, contribution of authors, continent, scale of industry, implemented approaches, focused industry, tools and techniques used in phases of Six Sigma methodology, and performance indicators used in Six Sigma implementation. Then after, future scopes of research opportunities are derived based on significant findings. Findings The literature revealed that: Very few work was undertaken on the implementation of Six Sigma in various manufacturing industries like ceramic, paper, gems and jewelry, cement, furniture, stone, fertilizer, forging, paper and surface treatment industries. Most of the researchers have considered very few performance indicators to identify the improvement after Six Sigma implementation. But, there is no clue regarding overall improvement in different perspectives after the implementation of Six Sigma. The financial indicators, personnel indicators, process indicators and customer indicators are useful to measure the overall improvement after the implementation of Six Sigma in the manufacturing sector. Research limitations/implications The study was carried out on the implementation of Six Sigma methodology in various manufacturing industries, and various performance indicators were identified while implementing the Six Sigma methodology. Case studies pertaining to service industries were not covered here. Originality/value Very little research has been carried out to measure the overall success of implementing Six Sigma methodology in manufacturing industries. This paper will provide value to students, researchers and practitioners of Six Sigma by providing insight into the implementation of Six Sigma in manufacturing industries.

Comparative study on adoption of sustainable supply chain management practices in Indian manufacturing industries

2019 ◽  
Vol 14 (4) ◽  
pp. 1006-1022 ◽  
Author(s):  
Deepak Mathivathanan ◽  
K. Mathiyazhagan ◽  
A. Noorul Haq ◽  
Vishnu Kaippillil
Keyword(s):  
Supply Chain ◽  
Supply Chain Management ◽  
Manufacturing Industries ◽  
Successful Implementation ◽  
Sustainable Supply Chain ◽  
Implementation Framework ◽  
Chain Management ◽  
Content Type ◽  
Sustainable Supply Chain Management ◽  
Manufacturing Sectors

Purpose Sustainable supply chain management (SSCM) concepts have received immense attention in the recent past in both academia and industries. Especially, manufacturing industries in developing countries realize the importance of adopting sustainability concepts in their supply chain. The SSCM adoption has not been to the same level across different manufacturing sectors and hence a single implementation framework will not have the same effect across sectors. This paper aims to compare the adoption level of 25 SSCM practices across three major manufacturing sectors, namely, automobile, electronics and textile, in an emerging economy, India. Design/methodology/approach A questionnaire-based data collection technique is used to obtain adoption levels of each of the identified SSCM practices on a five-point Likert-type scale with “1” representing not considering presently to “5” indicating successful implementation. Second, a hypothesis is framed and tested to compare the adoption levels across sectors using a one-way single-factor ANOVA followed by a post hoc test by Tukey’s test. Findings The results derived suggest that though the industries across different sectors are in the course of adopting SSCM practices, the level of adoption is found to be not the same. The textile sector has adopted the least, and the electronic sector edges ahead of the automobile sector in terms of successful transformation to SSCM. Originality/value This study focuses on the differences and similarities in the adoption of policies in the automobile, electronics and textile sectors using statistical data analysis tools. A total of 25 individual practices are identified from existing literature and classified into six groups, namely, management, supplier, collaboration, design, internal and society, based on their similarities. Based on a detailed questionnaire survey with industrial experts in relevant fields as respondents, the adoption levels of practices are rated individually and categorically.

scholarly journals Understanding barriers to circular economy: cases from the manufacturing industry

2020 ◽  
Vol 33 (4) ◽  
pp. 729-745 ◽  
Author(s):  
Bjoern Jaeger ◽  
Arvind Upadhyay
Keyword(s):  
Literature Review ◽  
Circular Economy ◽  
Manufacturing Industry ◽  
Manufacturing Sector ◽  
Research Question ◽  
Sustainable Growth ◽  
Sustainable Operations ◽  
Content Type ◽  
Start Up ◽  
Design And Production

PurposeMost companies include a commitment for sustainable growth involving a switch towards the circular economy (CE) model. The purpose of this paper is to present barriers to CE adoption identified by a literature review. The paper also addresses the particular challenges faced by manufacturers by answering the research question: What are the dominant barriers faced by the manufacturing industry in moving towards a CE?Design/methodology/approachThis paper presents a literature review of research identifying barriers for adopting to CE in the manufacturing sector. The literature review is followed by a case study identifying barriers to CE as seen by ten companies within manufacturing, including the GS1 global information standardisation agency used by all manufacturers.FindingsThe manufacturers investigated focus mostly on recycling and waste reduction. These policies have low or very low CE effect. High CE effect policies like maintenance and reuse targeting the CE ideal of no waste, are nearly non-existent. The results identified seven main barriers to the CE: (1) high start-up costs, (2) complex supply chains, (3) challenging business-to-business (B2B) cooperation, (4) lack of information on product design and production, (5) lack of technical skills, (6) quality compromise and (7) disassembly of products is time-consuming and expensive.Research limitations/implicationsThe data come from participants in a single country, Norway, although the manufacturers are multinational companies adhering to enterprise policies.Practical implicationsThis research shows that all the companies interviewed are well aware of the growing need for their company to move towards more sustainable operations involving CE concepts. The barriers identified are explored, and the findings could guide such companies in their efforts to move to maintenance, reuse, remanufacture and recycle (M+3R) operational model.Social implicationsThe study has found that the major barriers for implementation of CE are quality issues in recycled materials, supply chain complexities, coordination problems between companies, design and production of the product, disassembly of products and high start-up/ investment costs.Originality/valueThe research shows how the transition towards a CE takes place in manufacturing industries by studying the manufacturing sector.

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.

A hybrid framework based on SIPOC and Six Sigma DMAIC for improving process dimensions in supply chain network

2014 ◽  
Vol 31 (5) ◽  
pp. 522-546 ◽  
Author(s):  
Pratima Mishra ◽  
Rajiv Kumar Sharma
Keyword(s):  
Supply Chain ◽  
Six Sigma ◽  
Reference Model ◽  
Successful Implementation ◽  
Process Performance ◽  
Total Quality ◽  
Statistical Tools ◽  
Implementation Framework ◽  
Content Type ◽  
Hybrid Framework

Purpose – The purpose of this paper is to introduce a hybrid framework (suppliers, inputs, process, output and customers+define, measure, analyze, improve and control (SIPOC+DMAIC)) aimed at improving supply chain management (SCM) process dimensions in a supply chain (SC) network. Design/methodology/approach – Based upon the critical review of literature, process dimensions (average outgoing quality limit (AOQL), average outgoing quality (AOQ), process Z, defect per million opportunity) critical to SCM performance were identified. A framework consisting of three phases, i.e., design, implementation and results has been conceptualized and a case from paint industry is investigated. Implementation framework makes use of SIPOC model and Six Sigma DMAIC methodology. The goals of the study were achieved by using Six Sigma tools such as brainstorming sessions; root cause analysis, histograms, statistical tools such as control charts and process capability analysis. Findings – Authors made an attempt to propose a conceptual framework for improving process dimensions in a SC network. It is observed from the results that selection of appropriate strategies for improving process performance based upon experiences, and use of statistical tools by cross-functional teams with an effective coordination, guarantees success. Metrics such as AOQL shows the maximum worst possible defective or defect rate for the AOQ. Process Z helps to know about sigma capability of the process. Research limitations/implications – The framework so developed is tested in a single company manufacturing batches of paint. The study has important implications for the industry since it tries to integrate SCM process dimensions which would help in successful implementation of SCM practices in firm by following the DMAIC process. The framework enables the practitioners to investigate the process and demonstrate improvements using DMAIC which makes use of statistical tools. Originality/value – Although process dimensions related to SCM are critical to organization competitiveness, research so far has tended to focus on supply chain operations and reference model, balanced scorecard, total quality management, activity-based costing, just in time, etc., but in literature hardly any description of the SIPOC-DMAIC model to improve SCM process performance is provided. The use of statistics in DMAIC provides better insight into the process performance, and process control.

Analyzing Lean Six Sigma enablers: a hybrid ISM-fuzzy MICMAC approach

2017 ◽  
Vol 29 (3) ◽  
pp. 488-511 ◽  
Author(s):  
Gunjan Yadav ◽  
Tushar N. Desai
Keyword(s):  
Expert Opinion ◽  
Six Sigma ◽  
Large Scale ◽  
Lean Six Sigma ◽  
Content Type ◽  
Micmac Analysis ◽  
Fuzzy Micmac ◽  
Implementation Failure ◽  
Industry Professionals ◽  
Practical Implications

Purpose The purpose of this paper is to identify Lean Six Sigma enablers (LSSEs) and analyse the interaction among the enablers via a hierarchical model developed by employing interpretive structural modelling (ISM) and determine the driving and dependence power of enablers through fuzzy MICMAC (Matriced’ Impacts Croise´s Multiplication Applique´ea´un Classement) analysis. Design/methodology/approach An expert group of industry professionals and academicians is consulted at the initial stage as an input for ISM methodology to explore the paired relationship among LSSEs for each parameter of Lean Six Sigma (LSS) implementation. The outcome of ISM is further utilized by fuzzy MICMAC analysis to discover the enablers that are strong drivers and highly dependent. Fuzzy set is included in MICMAC analysis in order to obtain more precise output and effective model. Findings In total, 20 key enablers are identified through a literature review and expert opinion that emerged as the most significant factors towards LSS implementation. The identified enablers are portrayed into a structural form representing as input and output variables. Later, the driving and the dependence power of each enabler is presented in cluster form. Research limitations/implications The paired relationships among LSSEs are obtained through the interpretation made by the experts. The judgments of experts are subjective and may be biased; as difference in expert opinion may influence the final outcome. Conducting a large-scale survey may provide a better catch for interactions of LSSEs. Practical implications This study provides strong practical implications for researchers as well as industry practitioners. The industry professionals must deliberately focus on the identified LSSEs more conservatively during LSS implementation and the top management should plan strategically to avoid any implementation failure. Originality/value The present study identifies 20 crucial enablers of integrated LSS and presents them in a hierarchical form which will be beneficial for researchers and practitioners. The interactions among the enablers shown in cluster form will help in better execution of LSS.

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