Sigma Adoption Research Articles

Enablers for green lean six sigma adoption in the manufacturing industry

PurposeThe objective of this article is to identify the relationships between the enablers in the implementation of Green Lean Six Sigma (GLSS) in the Mexican manufacturing industry (MMI).Design/methodology/approachTo create the survey instrument, the authors did an extensive literature research, which they then applied in the MMI to find the relationships between enablers and their impact on the positive effects of implementing GLSS projects. Using exploratory and confirmatory factor analyses (EFA and CFA), the data were empirically and statistically corroborated. Furthermore, the authors validated the hypotheses that support the research using the structural equation modeling (SEM) approach in SPSS Amos.FindingsThe findings reveal that leadership has a positive impact on social and economic benefits (EcB), as well as an indirect impact on the environmental benefits (EB) of GLSS projects, with organizational involvement (OI) and performance measurement (PM) functioning as mediators.Practical implicationsThis study represents an empirical reference for practitioners and researchers pursuing high-quality, low-cost, environmentally and socially sustainable products or processes through the implementation of GLSS projects in the manufacturing industry.Originality/valueThis study provides a statistically validated model using the SEM technique to represent the relationships between GLSS enablers in the MMI.

Assessment of risk factors to Green, Lean, Six Sigma adoption in construction sector: Integrated ISM-MICMAC approach

The construction industry consumes significant resources, emits considerable pollutants, and generates substantial waste. Green, Lean, Six Sigma (GLS) is an emerging paradigm to control waste, carbon footprint, resource conservation, non-value-added activities, and cost. However, limited focus has been given to the risks involved in GLS construction projects (GLSCPs). This research explored risk factors (RFs) to GLSCPs based on literature review and expert judgments. Brainstorming sessions were conducted to validate the RFs and establish mutual interactions among them through experts' opinions. A 4-level structural model was extracted through Interpretive structural modeling (ISM). The Matriced Impacts Croise's Multiplication Appliqée a UN Classement (MICMAC) was integrated to assess the ‘driving’ and ‘dependence’ power of the RFs. The results show that all RFs are crucial and impact GLSCPs, but the most critical are ‘unstable inflation,’ ‘fluctuations in interest rate,’ and ‘fluctuations in exchange rate.’ This study enhances managers' and policymakers' understanding of RFs associated with GLSCPs and supports effective risk management for successful GLS implementation in construction projects.

Exploration and Investigation of Green Lean Six Sigma Adoption Barriers for Manufacturing Sustainability

The increased awareness about the effect of operations on sustainability dynamics and governmental pressure to cut emission rates has forced industries to adopt sustainable approaches such as Green Lean Six Sigma (GLSS). Despite increasing interest in GLSS, very limited research has focused on its implementation and no research has investigated barriers that hinder GLSS execution. This article investigates GLSS implementation barriers, their relationship, and removal of same in the manufacturing sector. In this article, 18 GLSS barriers have been recognized through literature review and formulated into logical groups using principal component analysis. This article pioneers with decision-making trial and evaluation laboratory with intuitionistic fuzzy (IF) set to prioritize barriers and handle the important and causal relationship among the same. The results of the article were validated through the IF best-worst method (BWM). The results reveal that management-related barriers are the top ranked followed by environmental and organization barriers with BWM weights 0.5283, 0.1704, and 0.1035, respectively. This provides impetus to policymakers for the induction of GLSS in business organizations to make harmony between economic development and environmental sustainability.

Enhancing sustainable supply chain performance by adopting sustainable lean six sigma-Industry 4.0 practices

PurposeThe Sustainable Lean Six Sigma (SLSS) adoption approach, advancements in Internet technologies and the use of Industry4.0 technologies has resulted in faster customer need fulfilment. The Industry4.0 technologies have resulted in a new paradigm where strategic and operational decisions are in favour of profitability and long-term viability. The purpose of this study is to identify Industry4.0-SLSS practices and sustainable supply chain performance metrics, as well as to develop a framework for decision-makers and managers to make supply chains more sustainable.Design/methodology/approachThe 33 Industry4.0-SLSS practices and 24 performance metrics associated with the sustainable supply chain are shortlisted based on extensive literature review and expert opinion. The Pythagorean Fuzzy Analytical Hierarchy Process (PF-AHP) approach is used to evaluate the weights of Industry4.0-SLSS practices after collecting expert panel opinions. The Weighted Aggregated Sum Product Assessment (WASPAS) methodology used these weights to rank performance metrics.FindingsAccording to the results of PF-AHP, “Product development competencies (PDC)” are first in the class of major criteria, followed by “Advanced technological competencies (ATC)” second, “Organisational management competencies (OMC)” third, “Personnel and sustainable competencies (PSC)” fourth and “Soft Computing competencies (SCC)” fifth. The performance metric “Frequency of NPD” was ranked first by the WASPAS method.Research limitations/implicationsThe proposed paradigm helps practitioners to comprehend Industry4.0 technology and SLSS practices well. The identified practices have the potential to boost the sustainability and supply chain's performance. Organizational effectiveness will benefit from practices that promote a sustainable supply chain and the use of developing technology. Managers can evaluate performance using performance metrics that have been prioritized.Originality/valueThe present study is one of the unique attempts to establish a framework for enhancing the performance of the sustainable supply chain. The idea of establishing Industry4.0-SLSS practices and performance measures is the authors' original contribution.

A systematic literature review of lean six sigma adoption in European organizations

PurposeThe purpose of this paper is to review of the literature about lean six sigma (LSS) implementation in European organizations written by academics or practitioners from European institutions to extract useful conclusions about LSS adoption in European companies and to suggest direction for future research concerning the broader LSS application in them.Design/methodology/approachThis study has been conducted by reviewing 58 papers, found in top journals, coming from European institutions that present studies of European companies and fulfill the selected inclusion criteria.FindingsThe analysis of the literature revealed the level of penetration of the LSS methodology in organizations of each European country. The study of the papers revealed the sectors and the size of companies that are more active in LSS application, the method used in each project, the tools which are deployed and the interconnection between LSS and other topics through the project implementation.Research limitations/implicationsThe limited access provided by the authors’ institution only to three major publishers (Emerald, Elsevier, Taylor and Francis) and the focus of the search only in European organizations were the main limitations of this review.Practical implicationsThis paper provides both academics and practitioners with valuable insights about LSS implementation in European organizations, presenting a complete analysis framework of the literature and highlighting gaps for further research.Originality/valueAn extended and detailed analysis of LSS adoption in Europe has not been conducted before. This review presents a clear view about how LSS projects in European organization have been applied so far and suggests ways of how the literature could be enriched to facilitate the LSS implementation.

Factors impacting individual Six Sigma adoption

PurposeOrganizations spend considerable time and money educating individuals on Six Sigma; however, existing literature does not examine Six Sigma adoption at the individual level or the factors that impact individual Six Sigma adoption. The purpose of this paper is to increase the understanding of individual adoption of Six Sigma tools and methodology.Design/methodology/approachThis paper used a single-site field study in a manufacturing organization to empirically test and refine a theory of the factors impacting Six Sigma adoption at the individual level.FindingsReaction to training, project management and project infrastructure were found to be significant input factors for individual Six Sigma adoption with an R2 of 0.482, which indicates that about 48 per cent of the variation in Six Sigma adoption is explained by the input factors. All of the identified input factors were found to have a positive relationship with individual Six Sigma adoption, as well as positive correlations with each other.Research limitations/implicationsThis paper was not a controlled experiment or a longitudinal study, so it is not possible from the results of this research to prove causal relationships, although the literature supports a causal relationship between the input factors and outcome.Practical implicationsThe findings of this paper will be useful to practicing organizations which seek to improve individual Six Sigma adoptions, as well as inform future Six Sigma adoption research.Originality/valueSix Sigma adoption at the organizational level has been well documented in the existing literature. The successful adoption of Six Sigma in an organization is dependent, at least in part, to adoption Six Sigma at the individual level. A review of the existing literature indicates that there has been no research into individual adoption of Six Sigma tools and methodology.

Prioritising solutions for Lean Six Sigma adoption barriers through fuzzy AHP-modified TOPSIS framework

PurposeThis paper aims to guide about prioritisation and ranking of the solutions and overcoming barriers to facilitate the adoption of Lean Six Sigma (LSS) by using a hybrid framework.Design/methodology/approachIt identifies LSS barriers and solutions to facilitate LSS adoption through literature review and by involving subject experts. The study makes use of fuzzy set theory and proposes a fuzzy analytical hierarchy process (AHP)-modified TOPSIS (technique for order preference by similarity to ideal solution) framework. It uses sensitivity analysis to establish framework robustness.FindingsThe key findings of this techno-managerial study are identification and prioritisation of 27 LSS barriers and 22 solutions to overcome adoption challenges, proposition and usage of fuzzy AHP-modified TOPSIS framework, guidance regarding where to focus for facilitating LSS adoption and ensuring robustness using sensitivity analysis, which establishes insignificant deviation in rankings when criteria weights are altered.Research limitations/implicationsSome biasness and subjectivity may exist during pairwise comparisons as human judgements are involved.Practical implicationsHandling a hybrid solution like LSS is never easy. It is expected that the study will help industry professionals to plan their LSS adoption attempts effectively. Guidance regarding LSS barriers will assist in observing necessary precautions to avoid failures. It will open up new research fronts for researchers also.Originality/valueLiterature is full of studies regarding LSS barriers and its rankings. It is very rare to witness a study like ours, which discusses the barriers and links with solutions and its prioritisation. Proposed hybrid framework for a hybrid techno-managerial approach such as LSS is unique and acts as the roadmap for smooth implementation.

Six Sigma in healthcare: a systematic review of the literature

PurposeThe purpose of this paper is to illustrate the systematic role played by Six Sigma methodology in improving the quality of healthcare. The literature review identifies the relevant opportunities for successful introduction and development of Six Sigma approach in healthcare sector.Design/methodology/approachA systematic methodology to identifying literature on Six Sigma in healthcare is presented. Web of Science, Medline, Emerald Insight, ASQ and ProQuest databases (1998-2016) were searched, and 68 papers of fair methodological quality were identified.FindingsThe findings of the systematic review reveal a growing interest in research on Six Sigma adoption in healthcare. The findings indicate that Six Sigma applications in healthcare have been focused on the entire hospital with no real focus on a particular department or function. The key findings on benefits, success factors, challenges and common tools of Six Sigma from the existing literature are also presented in the paper.Research limitations/implicationsThe papers included in the systematic review were peer-reviewed papers available in English. Due to these limitations, relevant papers may have been excluded. Moreover, the authors have excluded all conference and white papers for their inclusion in this study.Originality/valueThis paper can serve as a guide on how Six Sigma approach can be applied to improve the quality of healthcare. The authors also believe that this is possibly the most comprehensive systematic literature review on the topic and will set the foundation for various research avenues based on the key findings of this study.

A Lean Six Sigma framework to enhance the competitiveness in selected automotive component manufacturing organisations

Background: Currently, globalisation, economic uncertainty and fluctuating market demands prompt leaders all over the world to improve their operations and to enhance innovations in processes, products and services in a very reactive manner. Literature shows that the adoption of an integrated Lean Six Sigma tool can assist them to compete with the rest of the world in a manner where productivity, quality and operational costs reduction are crucial for economic success. Aim: This article investigates the integration of Lean and Six Sigma tools as a unified approach to continuous improvement and develops a Lean Six Sigma framework for selected automotive component manufacturing organisations in KwaZulu-Natal (KZN), South Africa. Method: The quantitative methods of research were adopted. The target population (42) was organisations within the Durban Automotive Cluster of which five were used for the pilot work. An empirical study was conducted using a survey questionnaire in measurable format to gather practical information from the sample organisations on the status of their existing business improvement programmes and quality practices. Results: The results of the study demonstratedthat the organisations had a very low success rate of Lean and Six Sigma adoption as standalone systems, as they found it difficult to maintain the transition from theory to practice. Conclusion: Hence the adoption of an integrated Lean Six Sigma approach was absent and it can be concluded that the proposed Lean Six Sigma framework affords the KZN automotive sector a unique opportunity to integrate and operate with both tools of quality that complement its management style and industry demands.

ISM and Fuzzy MICMAC application for analysis of Lean Six Sigma barriers with environmental considerations

PurposeThe purpose of this study is to prioritize and analyze the barriers that affect Lean Six Sigma (LSS) adoption with environmental considerations.Design/methodology/approachTo find interrelationships and mutual influences among the identified barriers, an integrated interpretive structural modeling (ISM) and Fuzzy MICMAC (Matrice d’Impacts Croisés Multiplication Appliqués à un Classement approach was applied). In total, 20 crucial barriers that affect LSS adoption with environmental considerations have been derived from the literature and in consultation with experts hailing from the industry and academia.FindingsBased on the analysis, the most dominant and dependent barriers that affects LSS adoption with environmental considerations have been identified. The barriers, namely, “lack of top management commitment”, “lack of training and education” and “lack of funds for green projects”, occupy the base segment of the ISM hierarchy; the barriers, namely, “difficulty in adopting environmental strategies”, “stringent government policies”, “negative attitude towards sustainability concepts”, “improper communication” and “lack of defect monitoring analysis”, occupy the top level of the ISM hierarchy.Practical implicationsThe analysis helped in identifying and prioritizing the barriers that affect LSS adoption with environmental considerations using a mathematical approach. This approach is also helpful for practitioners to focus on removing the key dominant barriers and to enable LSS adoption with environmental considerations smoothly.Originality/valueThe analysis helped in identifying and prioritizing the barriers that affect LSS adoption with environmental considerations using the Fuzzy MICMAC approach which has not been attempted in the past. The structural model is developed holistically based on the inputs gathered from practitioners and academicians to ensure practical validity. Also, this approach is helpful for practitioners to focus on removing the key dominant barriers and enabling them to deploy LSS concepts with environmental considerations smoothly.

Making the foreign familiar: The influence of top management team and board of directors characteristics on the adoption of foreign practices

This paper examines the firm-level antecedents of Six Sigma adoption in Korea. Our results indicate that firms with top executives and board members having work experience in the foreign country where the focal management practice originated and was popularized are more likely to adopt this practice. Furthermore, firms’ exposure to foreign investors exerts a direct effect and also moderates the impact of foreign work experience on adoption. Prior work experience in the country of practice origin reduces the uncertainty inherent in cross-border adoption by providing executives and board members with greater insight into the presumed benefits of the focal practice.

Six Sigma adoption in public utilities: a case study

This paper presents a real-life illustration of a Six Sigma Define–Measure–Analyse–Improve–Control framework blended with innovative tools such as perception analysis, interrelationship diagram, affinity diagram, and Gemba investigation to identify defects and guide process improvements in energy meter-reading in the context of public utilities. The key defects exposed by the analysis of meter-reading data for two months were wrong reading (discrepancy in the data read from the meter), wrong NA (erroneous recording of ‘wrong address’ status), and wrong PL (erroneous recording of ‘premises locked’ status). The remedial actions that followed the analysis resulted in a cost saving of INR 0.25 million per annum owing to reduction in the follow-ups for Narela District alone. The study provides a stimulus for the wider application of systematic and data-driven approaches for the measurement and improvement of services.

Forces affecting one Lean Six Sigma adoption process

Purpose – The purpose of this paper is to identify forces (in the form of converters and inhibitors) of Lean Six Sigma adoption by studying the gradual adoption of Lean Six Sigma in a medium-sized Swedish manufacturing company. The paper suggests how the converters and inhibitors interact toward increased maturity of the adoption and, in this case, stagnation thereof. Design/methodology/approach – Thirteen interviews were recorded and analyzed to identify converters that were moving the process forward or backward, as well as inhibitors that caused it to linger. Findings – It was discovered that activities that had initially moved the process forward were not sufficient to move it beyond its current point. However, an increased knowledge of Lean Six Sigma throughout the organization now prevents the process from moving in the opposite direction. In this medium-sized Swedish manufacturing company, Lean Six Sigma becomes a framework for thought and communication during Lean work. Research limitations/implications – The study benefited from considering forces pushing the process forward as well as backward. Thus, the authors suggest that future studies will benefit from focusing beyond critical success factors that may at times are static in nature. As a limitation, for discussions about the past, the memories of interviewees, generally, may have a tendency to be biased. Originality/value – The paper contributes knowledge of Lean Six Sigma adoptions and how they may attain greater future success by reporting on difficulties and setbacks in the current gradual adoption process in a chosen company.

Process improvement in farm equipment sector (FES): a case on Six Sigma adoption

Purpose – The purpose of this study is to exhibit how a leading company operating in farm equipment sector (FES) in India utilized Six Sigma statistical tools to reduce field failures of tractor assembly and thereby improved customer satisfaction. Design/methodology/approach – The study adopted Six Sigma define-measure-analyse-improve-control (DMAIC) methodology in order to identify numerous critical process improvements. Findings – After completing the define, measure and analyze phase, it was found that the processes of lapping, spring scragging, and assembly of valve body were incapable. The major recommendations made during the improve phase were to change the hydraulic oil; replacement of manual grinder with tool and cutter grinder for flat drill grinding; automation of lapping system; improvement in spring scragging system, change in piston design, etc. As a result of the implementation of remedies, field failure reduced by 95 percent producing a cost saving of almost INR 4.366 million/annum. Originality/value – This specific case demonstrates the successful application of Six Sigma DMAIC methodology in FES for driving down the field failures and improved customer satisfaction.

Six Sigma adoption: Operating performance impacts and contextual drivers of success

We assess the operational impacts of Six Sigma program adoptions through an event study methodology, comparing financial data for 200 Six Sigma adopting firms against data for matched firms, which serve as control groups for the analyses. We employ various matching procedures using different combinations of pre-adoption return on assets (ROA), industry, and size as matching criteria. By comparing performance outcomes across a hierarchy of operating metrics, we establish a pattern of Six Sigma adoption effects that provides strong evidence of a positive impact on ROA. Interestingly, these ROA improvements arise mostly from significant reductions in indirect costs; significant improvements in direct costs and asset productivity are not evident. We also find small improvements in sales growth due to Six Sigma adoption. Cross-sectional analyses of the performance results reveal that distinctions in Six Sigma impacts across manufacturing and service firms are negligible. Interestingly, we find that the performance impact of Six Sigma adoption is negatively correlated to the firm's quality system maturity (indicated by prior ISO 9000 certification). Further analyses of manufacturing and service firms reveals that Six Sigma benefits are significantly correlated with intensity in manufacturing, and with financial performance before adoption in services. We discuss the implications of these findings for practice and for future research.

Implementing Six Sigma in Saudi Arabia: An empirical study on the fortune 100 firms

This paper presents the results of a survey that gathered evidence regarding the current status of Six Sigma adoption and implementation in Saudi Arabia. Although Six Sigma has become the focus of business for a quarter of a century, the philosophy has not gained the same attention in developing countries. Moreover, little academic research has been carried out on the extent of Six Sigma implementation in these countries. The study focuses on Six Sigma implementation among the fortune 100 manufacturing and service firms in Saudi Arabia since they represent the most important organisations operating in the country and could serve as an indicator for the extent of Six Sigma adoption. The results indicate that the rate of Six Sigma implementation is less than 32% of respondents. Reasons behind Six Sigma implementation, popularity of Six Sigma compared with other similar initiatives, Six Sigma implementation success factors, tools and techniques used, level of training, barriers and impediments in the implementation and benefits gained from implementation are investigated and compared with the literature. Moreover, the findings suggest that there is no significant difference in the level of most of Six Sigma practices between manufacturing and service firms which asserts that service firms recognise Six Sigma and are using it to boost performance

An institutional theory perspective on Six Sigma adoption

PurposeThe purpose of this paper is, first, to utilize institutional theory to assess motivation for the adoption of Six Sigma. Second, to examine the role of an organization's innovation implementation climate and the fit between the innovation considered and the values of the organization's members on the implementation of Six Sigma. Third, to study the impact that the adoption and implementation of Six Sigma has on organizational performance.Design/methodology/approachMethods advocated in case study research were employed in the conduct of seven case studies. The research protocol consisted of identifying organizations in a variety of manufacturing industries, and conducting focused interviews with a minimum of three respondents in each company in order to improve validity.FindingsThis paper suggests that institutional theory proves to be an effective means by which to examine the adoption of Six Sigma. In addition, support for innovation implementation model suggested by Klein and Sorra is found. Each of the studied firms reported performance improvements as a result of the adoption and implementation of Six Sigma.Originality/valueThis paper contributes to a better understanding of Six Sigma adoption, implementation, and implementation effectiveness of Six Sigma by exploring how it is applied in different manufacturing contexts.

Benchmarking Six Sigma application in Brazil

PurposeThe purpose of this paper is to present part of the results from a survey on Six Sigma, more specifically to identify the best practices in the use of the Six Sigma methodology.Design/methodology/approachData were collected in an exploratory‐descriptive survey on Six Sigma adoption in companies operating in Brazil. Then, the paper presents and discusses best practices in Six Sigma application.FindingsThe results point out relevant aspects related to the professionals involved with the program, the number of projects developed per year, as well as the return on investments made by companies. It is concluded that a good proportion of respondents adopt best practices according to the literature, but the subject needs a more detailed investigation of the financial benefits achieved with its application.Research limitations/implicationsIt is important to stress that the importance of some of these exemplary aspects vary with the type of company but, overall, they might be generalised within the sample.Practical implicationsThe results show that there are relevant points when applying Six Sigma that should be considered by companies interested in adopting it.Originality/valueAs the application of Six Sigma is relatively recent and there is little data published about its utilisation in a developing country, it is important to expand knowledge on this subject. The best practices identified in this paper may be useful to Six Sigma users and academics.