Abstract
Abstract Implementation of Lean and Six Sigma methodologies enable companies to boost their competitiveness and their efficiency. However, the adoption of these approaches is very much restricted in the Textile and Clothing sector in Morocco. In fact, despite all the advances in these methodologies and practical approaches, defining a rational implementation strategy such as the adequate chronology and the prediction of the expected success level are still a part of a fierce debate and an impediment for practitioners. The result is that only 11 companies out of 1,200 Moroccan clothing companies have successfully implemented Lean and Six Sigma. This article, based on an intelligent model, draws up a support tool to the clothing stakeholders, or otherwise aims to successfully integrate Lean and Six Sigma using Deep Learning. The neural network was trained for the prediction of success level rate and customizing of Lean and Six Sigma implementation chronology with the help of weights and maturity of a set of common critical success factors (CSFs). These CFSs were selected as input data. Then, the dataset have been used for training, testing, and validating the neural network model. To evaluate the trained network, 25% of the data have been used and a tuning hyperparameter process has been designed to reinforce the model performance. For the performance indices such as Categorical Cross Entropy (CCE), the defined loss function, accuracy, and precision have been evaluated and optimized. The developed model can then define the adequate chronology and predict success level with an accuracy of 97%. The trained neural network was then applied to a clothing company as a guide to the success of its continuous improvement project.
Highlights
Lean Six Sigma is a combination of two powerful continuous improvement methodologies: Lean Management and Six Sigma
The choice of the implementation chronology or sequencing: (Lean followed by Six Sigma, Six Sigma followed by Lean, or both Lean and Six Sigma simultaneously) could have a direct effect on the implementation success level achieved [6]
To correctly manage the integration of the continuous improvement approaches of Lean and Six Sigma and at the same time guarantee the highest success level, a methodical strategy based on the assessment of their critical success factors (CSFs) is recommended
Summary
Lean Six Sigma is a combination of two powerful continuous improvement methodologies: Lean Management and Six Sigma. Lean philosophy focuses on reducing wastes and lead time through the operational process [1], while Six Sigma removes defects and increases quality. Each of these methodologies has become popularized individually by its successful implementation at pioneer companies such as TOYOTA and General Electric [2]. The choice of the implementation chronology or sequencing: (Lean followed by Six Sigma, Six Sigma followed by Lean, or both Lean and Six Sigma simultaneously) could have a direct effect on the implementation success level achieved [6]. The question of proper and fruitful sequencing causes a debate in the literature: Some authors insist on deploying The integration of the two approaches can achieve better results than what either approach could not achieve alone [3] and provides a more significant impact to the organizational culture and the bottom line [4, 5].
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