Academic leadership and Lean Six Sigma

Impact of perceived importance of cultural readiness factors on perceived importance of Lean Six Sigma success factors for manufacturers

Purpose

This study aims at investigating the impact of the perceived importance of critical cultural readiness factors (CRFs) is on perceived importance of Lean Six Sigma (LSS) technical critical success factors (CSFs) in UK manufacturing sector.

Design/methodology/approach

A survey questionnaire through a multiple embedded case study was conducted. The study involves surveying people in the manufacturing firms followed by non-parametric Kruskal–Wallis test to study the relationships.

Findings

It was found that the people's perception towards impact of CRFs on technical CSFs of LSS projects is different depending upon each CRF, demographic factors and technical CSFs. This means that particular CRFs need to be prioritised to address LSS technical CSFs.

Research limitations/implications

The study fills the research gap in investigating the perception of people towards inter-relationship of cultural or soft CSFs of LSS and technical or hard CSFs of LSS in manufacturing firms. Nevertheless, the authors suggest further multi-case study analysis covering different manufacturing fields as future studies.

Practical implications

The study is crucial for managers financially to be ready to invest on a successful LSS project and it helps them to diagnose the cultural causes of failure in a more timely way and effectively.

Originality/value

This is a preliminary study focussing on analysing inter-relationship between perceived importance of soft readiness factors and perceived importance of implementing success factors as a missing jigsaw in the current literature.

A thorough Six Sigma DMAIC application for household appliance manufacturing systems

Purpose

The purpose of this study is to analyze door-panel alignment defects seen in built-in ovens manufactured in one household appliances company's plant. Alignment defects in oven door panel substantially affect aesthetics of the product which is an important aspect in driving customer preference and satisfaction. Therefore, this study aimed to increase the initial 3.1 sigma level of oven-manufacturing process to at least 4 sigma level by decreasing a particular door-panel alignment defect, which constituted 67.7 percent of the overall alignment defects.

Design/methodology/approach

The goals were achieved through a structured Six Sigma implementation with lean element by utilizing various Six Sigma tools such as workflow, Pareto-analysis, measurement system analyses, control-charts, process capability analysis, cause-and effect-diagram and hypotheses tests. A non–value-added step was also eliminated through the lean approach.

Findings

Through Six Sigma implementation, the initial 3.1 sigma process performance level has been increased to 4.4 sigma level leading to substantial decrease in alignment defects.

Originality/value

In the quality management literature, not many papers directly deal with aesthetics and appearance problems of the products especially in the household appliances industry. Moreover, hypothesis testing is not frequently used in Six Sigma implementations in the literature. In addition to limited usage of hypothesis testing, very few studies conducted a thorough measurement system analysis. Considering these gaps in the Six Sigma literature, this study fills an important gap in research by implementing a detailed Six Sigma study, enhanced with hypothesis testing and a thorough measurement system analysis, on the aesthetics and appearance of the product.