Six Sigma with C-K theory for innovations in operational excellence: a case study

Characterization of Lean Six Sigma projects in healthcare settings: empirical research

Purpose

This paper aims to characterize a sample of Lean Six Sigma (LSS) projects in healthcare settings and discuss some specificities of operational excellence (OPEX) initiatives in hospitals and healthcare organizations in the USA.

Design/methodology/approach

A content analysis involving a sample of 23 documents shared by US hospitals was performed in order to achieve the research objectives. Such analysis was based on a conceptual framework developed from the literature review. It was also applied to a quantitative approach, including descriptive statistics, hypothesis testing and correspondence analysis that supported the research.

Findings

Most LSSH projects were focused on business transformation and strategic improvements. Simple techniques and tools were predominant such as descriptive statistics, process mapping, 5S and spaghetti charts, usually implemented by Green Belts and Black Belts through the define, measure, analyze, improve and control (DMAIC) method. In addition to the expressive findings reported, these projects' results have been aligned with lead time and operational cost reduction, quality improvement and capacity increase.

Research limitations/implications

The study adds knowledge to the OPEX literature by analyzing the Lean Six Sigma healthcare (LSSH) in hospitals and healthcare institutions in the USA. It also demonstrates that different approaches, such as the kaizen event and DMAIC project show different results according to some techniques and tools applied in the hospital environment.

Originality/value

The empirical evidence presented in this study provides scenery of the LSS practices in the healthcare settings, highlighting the implementation areas, outcomes, tools and techniques mostly used in the North American healthcare institutions.

G, Koul R, Cudney EA, Chakraborty A. A study on critical failure factors of Design for Six Sigma in Indian companies: results from a pilot survey

Purpose

While Six Sigma (SS) has been deployed effectively in Indian manufacturing and service sectors as a process improvement methodology, the implementation of Design for Six Sigma (DFSS) for robust product and service development has not shown noticeable results. Therefore, this article aims to determine the critical failure factors (CFFs) of DFSS in the Indian context.

Design/methodology/approach

The paper presents the results of a pilot survey on the CFFs of DFSS in Indian companies. The survey participants were specialists in DFSS who have been involved in DFSS projects in their past and present companies. Moreover, the pilot study participants were DFSS Champions, Master Black Belts, Black Belts and Green Belts from the manufacturing and service sectors.

Findings

Company-wide applications of DFSS are very limited in India. Most of the DFSS project failures are reported in the Analyse phase of the project. The results indicated that all 18 CFFs used in the survey have a significant impact on project failures. Also, it was determined that all CFFs are positively correlated with each other. Further, a strong correlation was observed between the voice of the customer (VOC) and project selection and prioritisation. In addition, effective training showed a strong correlation with the right selection of tools.

Research limitations/implications

The pilot survey was based on a limited sample size. Moreover, the study is confined to only the Indian context and data were collected through the authors' networks. However, respondents were proficient, certified and involved in DFSS project deployment in the manufacturing and service sectors. Therefore, the study's findings are useful and meaningful to draw robust inferences.

Originality/value

To the best of the authors' knowledge, this is the first empirical study conducted in the Indian context to identify the reasons for DFSS project failures. The study's findings can aid academicians and practitioners in comprehending and critically examining the CFFs of DFSS before executing a project. Moreover, the research outcome motivates policymakers to create an ecosystem to effectively adopt DFSS for start-ups and micro, small and medium enterprises (MSME) to ensure a circular economy and support the “Atmanirbhar Bharat” initiative.

Proposed guidelines for treatment of recurrent failures for sustainability of results in the post-project improvement stage process

Purpose

The maintenance of process improvement programs within organizations is not an easy task. Some processes do not maintain the results achieved with the improvement project and again present low performance shortly after completion of the project. This paper aims to identify the socio-technical causes responsible for the loss of process performance after applying improvement projects, in order to support the mitigation of the problem.

Design/methodology/approach

A systematic review of the literature was carried out, which allowed the selection of 28 articles. The empirical stage used the benchmarking technique, along a large Brazilian mining company with an international standard of production and quality. This organization has been using improvement projects for more than ten years.

Findings

The research complements the literature regarding the prioritization of the 26 identified failures and the identification of seven new failure factors and two resources. Findings in this study can be an inspiration for other organizations, considering the similarity of methodological aspects of improvement projects since internationally standardized methodologies such as Six Sigma, Lean, Kaizen and 5S are used.

Originality/value

The research presented a proposal of guidelines that corroborate to the mitigation of loss of process performance after improvement project.

Ten commandments for successful implementation of Design for Six Sigma

Purpose

This article aims to provide Design for Six Sigma (DFSS) practitioners, researchers and academicians with Ten Commandments to successfully deploy projects.

Design/methodology/approach

The commandments are the brainchild of four authors' experience and expertise for more than 15 years of DFSS deployment in the spectrum of fields as a consultant, researcher, academic and Master Black Belt in Six Sigma and general quality management and engineering disciplines. Thus ascertained commandments were validated and classified through the “Delphi Study” to ensure its applicability.

Findings

The Ten Commandments from authors' perspective include: alignment of DFSS with organisational strategy; top management support and involvement; listening to the voice of the customers (VOC); effective training programme for right project teams; project selection and prioritisation; linking DFSS with ISO international standards; linking DFSS with organisational learning and innovation; linking DFSS with the 4th Industrial Revolution; effective use of DFSS methodology and the integrated tools within the methodology and reward and recognition schemes.

Research limitations/implications

The commandments presented in this article are the authors' personal experience in different industrial scenarios and settings and demographical locations. The authors are planning to conduct a longitudinal survey to understand further insights of these commandments with the input of several DFSS Black Belts and Master Black Belts, academicians and leading researchers from various countries.

Originality/value

All the organisation's stakeholders can use this article as general guidelines to ensure effective deployment of the DFSS approach.

Analyzing barriers and strategies for implementing Lean Six Sigma in the context of Indian SMEs

Purpose

The purpose of this study is to investigate the barriers for implementing Lean Six Sigma (LSS) in small and medium-sized enterprises (SMEs) and present a framework that provides prioritized strategies to overcome the barriers.

Design/methodology/approach

The barriers and strategies are identified via a comprehensive literature review and validated by industry experts. The study uses the fuzzy Technique for Order of Preference by Similarity to Ideal Solution (fuzzy TOPSIS) to analyze the barriers and strategies for determining the prioritized list of strategies.

Findings

The findings reveal that there are sixteen barriers to LSS implementation in Indian SMEs. To overcome these barriers, this study reveals twelve strategies. The analysis shows that “effective management” is the most crucial strategy to overcome the barriers for implementing LSS in Indian SMEs.

Research limitations/implications

This research guides SMEs practitioners to efficiently and effectively implement LSS, which, in turn, can enhance the performance of SMEs.

Originality/value

This study contributes to the literature by integrating the strategies with the barriers for implementing LSS in Indian SMEs. Besides, this study provides the prioritized list of strategies to overcome the barriers for implementing LSS in Indian SMEs.

How do organizations implement an effective LSS initiative? A qualitative study

Purpose

Lean Six Sigma (LSS) is one of the most popular and widely used business improvement methodologies. However, many organizations discontinue LSS despite a plethora of studies on the critical success factors. The purpose of this study is to answer the research question how do organizations implement an effective LSS initiative?

Design/methodology/approach

Qualitative study is conducted on managers working in companies using LSS for a long time. The data were analysed using Colaizzi method.

Findings

Twelve factors were identified which were responsible for the effective implementation of LSS. They are financial performance, organization-wide LSS culture, organization-wide innovation culture, continuous training and retraining of employees on LSS, continuous top management support, linking LSS to business strategy, linking LSS to the customer, project selection strategy, communication, recognition and compensation systems, social benefits and green benefits.

Originality/value

This is the first study to investigate the effective implementation of LSS initiative in the organization.