scholarly journals Assessment of Critical Failure Factors for Implementing Lean Six Sigma in Manufacturing Industry: A case study

2021 ◽  
Vol 03 (01) ◽  
pp. 16-32
Author(s):  
Swarnakar Vikas
Keyword(s):  
Continuous Improvement ◽  
Six Sigma ◽  
Manufacturing Industry ◽  
Implementation Process ◽  
Lean Six Sigma ◽  
Bottom Line ◽  
Negative Effect ◽  
Leading Position ◽  
Tools And Techniques ◽  
Failure Factors

In the present scenario manufacturing industries have been facing problem-related to cost, quality, and customer satisfaction. To overcome such problems, the organizations are ready to adopt continuous improvement (CI) approaches such as Lean Six Sigma (LSS) which keeps them stable when the demand for products or services fluctuates. LSS is a breakthrough improvement approach that helps to improve the bottom-line result of the company by utilizing its tools and techniques. The successful adaptation of the LSS approach provides a significant improvement in key metrics but deficiency of proper implementation shows a negative effect. To prevent such a situation, need to know about their failure factors. The objective of the present study is to assess the critical failure factors (CFFs) for LSS framework implementation in manufacturing organizations. The leading CFFs for LSS have been identified and selected through a structured literature review and expert opinion. The CFFs based model for LSS implementation has been developed using the Interpretative Structural Modelling and Matrice d’ Impacts Croises Multiplication Appliquee a un Classement (ISM-MICMAC) approach. Previous studies related to such concerns have not developed a structural hierarchical model that is necessary to tackle CFFs towards the LSS implementation process. Such an interrelation helps decision-makers, planners to systematically guide about the barriers that affect the implementation process and help for further implementation success. The developed structured model will also help LSS practitioners, consultants, researchers to anticipate the potential CFFs to implement the LSS framework in their industry for continuous improvement and achieve a leading position in a competitive market.

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.

Deploying Lean Six Sigma framework in an automotive component manufacturing organization

2016 ◽  
Vol 7 (3) ◽  
pp. 267-293 ◽  
Author(s):  
Vikas Swarnakar ◽  
S. Vinodh
Keyword(s):  
Six Sigma ◽  
Assembly Line ◽  
Lean Six Sigma ◽  
Bottom Line ◽  
Defect Reduction ◽  
Automotive Component ◽  
Content Type ◽  
Component Manufacturing ◽  
Manufacturing Organization ◽  
Tools And Techniques

Purpose This paper aims to deploy Lean Six Sigma (LSS) framework to facilitate defect reduction and enhance bottom line results of an automotive component manufacturing organization. Design/methodology/approach LSS is a business process improvement strategy widely used in the manufacturing field for enhancing manufacturing organization performance. The integration of Lean and Six Sigma will enable the attainment of defects reduction by eliminating non-value-adding activities from production line. LSS framework has been developed with the integration of define–measure–analysis–improve–control (DMAIC) tools and techniques. Findings The finding of this study is that the LSS framework has been successfully implemented in automotive component manufacturing organization, and non-value-adding activities and defects from assembly line have been reduced. The proposed LSS framework applies lean tools within Six Sigma DMAIC approach to facilitate waste elimination and defect reduction. The developed framework with linkage of DMAIC tools and techniques reduces defects and non-value-adding activities with enhanced bottom line results. The implementation of proposed LSS framework shows effective improvement in key metrics. Research limitations/implications The developed framework has been test implemented in an automotive component manufacturing organization. In future, more number of studies could be conducted. Further, advanced lean tools and techniques could be included in the framework for increasing the effectiveness of production line. Practical implications The proposed LSS framework with linkage of DMAIC tools and techniques has been successfully implemented in an assembly line of automotive component manufacturing organization. This method is presently applied for an automotive component manufacturing organization; in future, the approach could be applied in different industrial sectors with addition of new tools and techniques for improving its effectiveness. Originality/value LSS framework has been designed and test implemented in an assembly line of an automotive component manufacturing organization. Hence, the inferences are practical and key results of the study.

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 CATEGORIZATION OF LEAN SIX SIGMA TOOLS AND TECHNIQUES BASED ON DMAIC FRAMEWORK

2019 ◽  
pp. 1-12
Author(s):  
Norshazwana Akmal Hanafi ◽  
Owe Kowang Tan ◽  
Chin Fei Goh
Keyword(s):  
Continuous Improvement ◽  
Six Sigma ◽  
Lean Six Sigma ◽  
Improvement Project ◽  
Tools And Techniques

Lean Six Sigma is like twins to continuous improvement project which can be managed by using DMAIC methodology. DMAIC methodologies consist of several tools and techniques, and these tools differ for different industries. Thus, this study seeks to explore and compare the experiences of various organizations from various industries undertaking DMAIC activities within their organization in order to sustain the performance and maximize their value. This paper provides an overview of each tool and techniques used in DMAIC stage.

Critical failure factors of Lean Six Sigma: a systematic literature review

2014 ◽  
Vol 31 (9) ◽  
pp. 1012-1030 ◽  
Author(s):  
Saja Albliwi ◽  
Jiju Antony ◽  
Sarina Abdul Halim Lim ◽  
Ton van der Wiele
Keyword(s):  
Literature Review ◽  
Systematic Literature Review ◽  
Six Sigma ◽  
Poor Quality ◽  
Lean Six Sigma ◽  
Future Research ◽  
Bottom Line ◽  
Content Type ◽  
Top Management Commitment ◽  
Failure Factors

Purpose – Lean Six Sigma (LSS) is a continuous improvement methodology that aims to reduce the costs of poor quality, improve the bottom-line results and create value for both customers and shareholders. The purpose of this paper is to explore the critical failure factors for LSS in different sectors, such as manufacturing, services, higher education, etc. Design/methodology/approach – The following research is based on a systematic literature review of 56 papers that were published on Lean, Six Sigma and LSS in well-known academic databases from 1995 to 2013. Findings – There are 34 common failure factors of LSS cited in this paper. There are some common factors for failure, such as a lack of top management commitment and involvement, lack of communication, lack of training and education, limited resources and others. Many gaps and limitations are discussed in this paper and need to be explored in future research. Originality/value – The paper is one of the first systematic literature reviews to explore the critical failure factors of LSS and discuss the top failure factors from different angles, i.e. countries’ evolution, organisations’ size (small- and medium-sized enterprises and large organisations) and industry nature.

Leveraging Lean Six Sigma: Reducing defects and rejections in filter manufacturing industry

2021 ◽  
Author(s):  
Prateek Guleria ◽  
Abhilash Pathania ◽  
Himani Bhatti ◽  
Kuldeep Rojhe ◽  
Dalgobind Mahto
Keyword(s):  
Six Sigma ◽  
Manufacturing Industry ◽  
Lean Six Sigma

scholarly journals The Lean Six Sigma Algorithm—A Pathway for Decreasing the Continuous Improvement Projects Failure Rate

Proceedings ◽  
2020 ◽  
Vol 63 (1) ◽  
pp. 47
Author(s):  
Karam Al-Akel ◽  
Liviu-Onoriu Marian
Keyword(s):  
Failure Rate ◽  
Continuous Improvement ◽  
Six Sigma ◽  
Lean Six Sigma ◽  
Manufacturing Processes ◽  
Timely Manner ◽  
Improvement Project ◽  
Project Failures ◽  
Specific Order ◽  
Selection Of

Even if Lean and Six Sigma tools are available for large audiences, many of the continuous improvement projects fail due to the lack of a pathway that ensures appropriate results in a timely manner. We would like to address this universal issue by generating, testing and validating an algorithm that improves manufacturing processes in a controlled manner. With a selection of the most valuable set of tools and concepts implemented in a specific order, a guideline for successful project implementation is proposed. Decreasing the overall number of continuous improvement project failures is the main scope of our algorithm and suggested methodology.

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.

Business survival and market performance through Lean Six Sigma in the chemical manufacturing industry

2019 ◽  
Vol 10 (2) ◽  
pp. 566-600 ◽  
Author(s):  
Peter Muganyi ◽  
Ignatio Madanhire ◽  
Charles Mbohwa
Keyword(s):  
Continuous Improvement ◽  
Six Sigma ◽  
Market Performance ◽  
Lean Six Sigma ◽  
Chemical Product ◽  
Business Survival ◽  
Content Type ◽  
Chemical Manufacturing ◽  
Product Manufacturing

Purpose The research paper aims to unveil the practical use of Lean Six Sigma and its effectiveness as a business survival strategic tool by a chemical product realization concern, as well as to establish the market and business performance impacts on the manufacturing entity. Design/methodology/approach A case study approach was pursued with a multi-national chemical manufacturing entity in South Africa. A comprehensive literature research was undertaken to establish the contemporary tools used for implementing Lean Six Sigma, and the classification and flow of tools and steps undertaken to ensure the successful and effective application of Lean Six Sigma in a manufacturing organization and the benefits derived. The critical success factors and reasons of ineffective use of tools are reviewed. To ensure that a comprehensive research was conducted which is relevant to the body of knowledge in engineering, recent articles on the application of Lean Six Sigma were selected and reviewed during the progress of the study to add impetus to the relevance of the findings. Findings The research findings were mainly based on the inferences obtained from a chemical product manufacturing concern in South Africa, to distinguish the efficacy and relevance of Lean Six Sigma as strategic business survival tool and imputing strategic resonance to corporate strategy. Research limitations/implications This research was limited to distinguishing Lean Six Sigma as a business survival strategic tool and an ultimate enhancer of market performance for a chemical product manufacturing entity. The implementation and evaluation of the Lean Six Sigma methodology as a business survival strategic and market performance enhancement option for the case study organization was entailed as the corollary of deductive resemblance to similar entities. Practical implications This study enables continuous improvement practitioners to evaluate the Lean and Six Sigma practices. The advantages posed by the simultaneous and optimized application of the two approaches versus individual application were assessed and verified to produce enhanced continuous improvement. This poses further challenges to scholars and academics to pursue further researches on the practicality of applying Lean Six Sigma as a strategic option. Originality/value The paper prompts the efficacy of well publicized methodologies and evaluates their implementation for strategic performance for manufacturing organizations. The practical application, constraints and resultant effects of deploying Lean Six Sigma were reviewed to give impetus to the methodology.

A directed content analysis of viewpoints on the changing patterns of Lean Six Sigma research

2019 ◽  
Vol 31 (4) ◽  
pp. 641-654 ◽  
Author(s):  
Bryan A. Rodgers ◽  
Jiju Antony ◽  
Zhen He ◽  
Elizabeth A. Cudney ◽  
Chad Laux
Keyword(s):  
Continuous Improvement ◽  
Six Sigma ◽  
Design Methodology ◽  
Lean Six Sigma ◽  
Current Status ◽  
Short Term ◽  
Content Type ◽  
Changing Patterns ◽  
Practical Implications

Purpose The purpose of this paper, builds on previous studies that explored the research patterns over 15 years, is to consider the current status of the integration of Lean and Six Sigma. More specifically, this research addresses whether Lean and Six Sigma are stronger together and explores the reasons why Lean researchers and practitioners may be less likely to integrate Six Sigma in their work. Design/methodology/approach The research utilises a survey of 25 established and respected academics and practitioners from 16 countries. The questionnaire is analysed using a direct content approach and coded in NVivo. Findings The findings suggest that challenges may lie in the perception and understanding of statistics as well as short-term rather than long-term focus on improvement. The findings also suggest that academics and practitioners believe that Lean Six Sigma has developed over time and will continue to develop and improve as a methodology rather than being replaced with a new methodology. Research limitations/implications The survey has a sample size of 25, albeit all respondents are established and very experienced practitioners and academics. Practical implications For organisations that are introducing or refreshing their continuous improvement initiatives, this research identifies some of the challenges and provides the opportunity to address them to maximise the opportunities for success and sustainability. Originality/value The value of this paper is that it further addresses the debate over the integration of Lean and Six Sigma for many organisations which still employ Lean alone, but beyond this it explores how they will continue to develop and whether they are a permanent edition to the quality management landscape or a transition to something else.

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