Employees factors importance in Lean Six Sigma concept

Analysis of critical success factors for successful integration of lean six sigma and Industry 4.0 for organizational excellence

Purpose

Manufacturing industries are facing dynamic challenges in today’s highly competitive world. In the recent past, integrating Industry 4.0 with the lean six sigma improvement methodologies has emerged as a popular approach for organizational excellence. The research aims to explore and analyze critical success factors of lean six sigma integrated Industry 4.0 (LSSI).

Design/methodology/approach

This research study explores and analyzes the critical success factors (CSFs) of LSSI. A three-phase study framework is employed. At first, the CSFs are identified through an extensive literature review and validated through experts’ feedback. Then, in the second phase, the initial list of CSFs is finalized using the fuzzy DELPHI technique. In the third phase, the cause-effect relationship among CFSs is established using the fuzzy DEMATEL technique.

Findings

A dyadic relationship among cause-and-effect category CSFs is established. Under the cause category, top management commitment toward integrating LSSI, systematic methodology for LSSI and organizational culture for adopting changes while adopting LSSI are found to be topmost CSFs. Also, under the effect category, organizational readiness toward LSSI and adaptability and agility are found to be the uppermost CSFs.

Practical implications

The study offers a framework to understand the significant CSFs for LSSI implementation. Insights from the study will help industry managers and practitioners to implement LSSI and achieve organizational excellence.

Originality/value

To the best of the authors’ knowledge, CSFs of LSSI are not much explored in the past by researchers. Findings will be of great value for professionals in developing long-term operations strategies.

Scoping review of the readiness for sustainable implementation of Lean Six Sigma projects in the manufacturing sector

Purpose

This work presents a synthesis of current literature published from 2010 to provide an overall understanding of the sustainable implementation of Lean Six Sigma (LSS) projects in terms of project approaches rather than outcomes.

Design/methodology/approach

A comprehensive and validated ten-step model was applied to conduct a scoping review with the following three broad phases: “review planning”, “review execution” and “review reporting”.

Findings

The analysis shows that while a few geographically and methodologically broad research studies have been conducted on LSS and green manufacturing integration, no studies have examined organisational culture or conducted readiness assessments on the sustainable implementation of LSS projects in the manufacturing sector.

Research limitations/implications

The present study contributes to existing knowledge by describing the current state of research on green LSS integration. The study also identifies a lack of research on the deployment of sustainable LSS projects for manufacturers. Further empirical analyses that include case studies must be conducted to assess the negative environmental impacts of LSS projects.

Originality/value

This study serves as an initial call for practitioners and research scholars to favour the sustainable deployment of LSS projects in manufacturing alongside the use of traditional approaches with a focus on costs, quality and delivery.

Exploratory study

Purpose

Employee engagement recently emerged as a promising mechanism to improve organisational effectiveness and accordingly reduce the performance gap. This paper empirically demonstrates which employee engagement dimension(s) act as the strongest dimension to enhance the levels of employee engagement and consequently organisational effectiveness.

Design/methodology/approach

This study used a quantitative approach, specifically a survey design, using a questionnaire to collect data. Regression analysis was applied to predict the impact of the employee engagement dimensions on the level of employee engagement in organisations and the impact of online/social media, as part of communication, on employee engagement.

Findings

The statistical analyses indicate that the dimensions organisational strategy and implementation, organisational commitment and team commitment are significant predictors of employee engagement. On-line/social media has a negative effect on employee engagement. However, according to the results, communication in organisations can be improved, especially by using online/social media more effectively.

Research limitations/implications

This includes low response rate from some groups.

Practical implications

The importance of secondary general management tasks, particularly motivation and communication, in mobilising employees to cooperate in pursuing organisational goals, became apparent. This study reflects the adverse effect of a lack of leadership and management skills, and ineffective use of online/social media on organisational performance, as reported in academic and practitioner research. Regardless, practitioners can apply the levers of motivation, via structural dimensions of organisation, to activate psychological presence which drives employee engagement and in turn facilitates strategy implementation and consequently organisational effectiveness. Scholars can modify their research agendas by investigating the “(un)availability” of human resources to improve organisational effectiveness.

Social implications

The costs of disengaged employees are high, in terms of productivity losses and the performance gap, with adverse consequences for society.

Originality/value

Employee engagement as a driver of strategy implementation is an overlooked area of research. This study offers a better explanation of employee engagement as a mechanism to improve strategy implementation, thus reducing the performance gap, and consequently waste. Employee engagement engenders employee support to pursue organisational goals, in a coordinated system of cooperation, and is produced by the structural dimensions of organisation, the parameters within which psychological presence is activated. Psychological presence drives employee engagement which enables employees to be available to implement strategy to achieve organisational goals and thus organisational effectiveness. Engagement at a broader level than individual is significant.

The moderating effect of industry clockspeed on Lean Manufacturing implementation in Zimbabwe

Purpose

The purpose of this paper is to analyze the moderating impact of industry clockspeed (IC) on the relationship between Lean Manufacturing (LM) practices and operational performance. A model for evaluating the impact of LM is developed and the moderating effect of IC is taken into consideration as a fundamental variable that affects the causal relationship between LM practices and operational performance.

Design/methodology/approach

A structural equation model was proposed and investigated across two groups based on IC level (Group 1: low IC and Group 2: high IC). A structured survey questionnaire was used to collect empirical data from 600 companies listed by the Confederation of Zimbabwean Industries. A total of 214 usable questionnaires were obtained giving a response rate of 35.6 percent. The data were analyzed using Smart PLS 3 and SPSS version 25.

Findings

The results revealed that LM practices directly and positively affected operational performance and IC had a positive moderation effect on the relationship between LM practices and operational performance. The results indicated that the structural equation model remained invariant across the groups. This showed that IC had a moderating effect on the relationship between LM practices and operational performance for both low IC and high IC industries.

Originality/value

The study analyzed the moderating effect of IC in Zimbabwean industries. The study will provide further evidence to managers on the impact of LM practices on operational performance in developing countries.

Identifying and evaluating synergies of Lean Six Sigma and knowledge management in deliberately interlocking application

Purpose

The purpose of this paper is to identify and evaluate potential synergies between the two management approaches Lean Six Sigma (LSS) and knowledge management. Although a strong interaction between them is suspected, there is only very little academic research on their possible interrelation available. This paper aims to close this research gap.

Design/methodology/approach

Based on a comprehensive literature review and a comparison of LSS and knowledge management two hypotheses on their interlocking application are formulated, discussed and evaluated.

Findings

Knowledge management supports and improves the application of LSS in various ways. In particular, the deliberate integration of communities of practice, information and communication technologies, and feedback and “lessons learned” sessions can develop potentially positive synergy effects and contribute positively to the success of LSS projects. In contrast, LSS turns out to be an inadequate methodology to significantly improve knowledge management, mainly due to the imprecise measurability of knowledge management processes.

Research limitations/implications

The findings are based on a literature review and are not supported by empirical evidence. Therefore, empirical research in this field is suggested.

Practical implications

Organizations using LSS could enhance their performance by integrating instruments of knowledge management, whereas they should critically examine LSS as a methodology for improving knowledge management.

Originality/value

Considering the existing research gap in this field, this paper encourages organizations using LSS to reflect on if and how they could integrate instruments of knowledge management into their practice to achieve better LSS results.

Modelling the barriers of Lean Six Sigma for Indian micro-small medium enterprises

Purpose

The purpose of this paper is to investigate the barriers of Lean Six Sigma (LSS) and develop the interrelationship among them using interpretive structural modelling (ISM) and Matriced Impact Croises Multiplication Appliquee a un Classement (MICMAC).

Design/methodology/approach

Using systematic literature review and expert’s opinions, 26 LSS barriers have been extracted and finalized through statistical analysis, that is importance-index analysis and corrected item minus total correlation methods. The statistical analysis of purified 22 LSS barriers has been carried out and consistency of finalized barriers has been checked through reliability statistical test in Statistical Package for the Social Sciences software. Finally, the contextual relationship among finalized LSS barriers is developed using ISM and MICMAC approach.

Findings

The ISM model indicates that insufficient management commitment and involvement, lack of resources, lack of training and education, lack of strategic thinking, lack of training funds are strategic factors; improper project selection, poor selection of employee for belt training, lack of total employee involvement, lack of awareness of about LSS are prudent factors; unclear vision, high implementation cost, resistance to culture change, weak supplier linkage, poor alignment between company’s goal and customer demand are burst factors. Furthermore, MICMAC analysis is splitting the LSSBs in four clusters according to their driving power and dependency. These results provide a clear mind-set to engineering manager for focusing more on LSS barriers according to their driving power and dependency.

Research limitations/implications

There may be biasness in making pairwise comparison matrix of barriers due to involvement of expert’s opinion as human error.

Practical implications

The outcome of this paper provides robust practical implication for LSS researchers and practitioners. The researcher and practitioners must consciously concentrate on the identified LSSBs more conventionally during LSS implementation, and they need to plan strategically to avoid any implementation failure.

Originality/value

For successful implementation of LSS in any organization, it is necessary and permeable to make strategy for controlling LSS barriers at initial stage. So this paper is a leading attempt to highlight main LSS barriers and interrelate them using ISM and MICMAC approach. It provides a clear path for tackling LSS barriers to engineering managers, researchers and consultants.

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

Purpose

Six Sigma is a well-established powerful business strategy for achieving operational excellence (OPEX). However, previous studies have suggested that the Six Sigma may negatively impact organizational creativity and innovation. The C-K theory is one of the most widely used technique for design reasoning which promotes the creativity and innovation. The purpose of this paper is to integrate the Six Sigma methodology and C-K theory for enhancing innovative capacity of Six Sigma for achieving OPEX.

Design/methodology/approach

The paper proposes an integration methodology of C-K theory and Six Sigma using the extant literature. Also, a case study is conducted based on the proposed integration model.

Findings

The paper suggests a step-by-step integration methodology for integrating Six Sigma with C-K theory for both (DMAIC and DMADV). The methodology when applied to a live case in mining logistics the results are very encouraging. The solution was cost effective and also technically superior compared to previous solutions.

Practical implications

The paper proposes a step-by-step methodology for the integration of Six Sigma with C-K tools. The methodology is practically applied in a live case. Organizations can use findings from this paper to implement an integration model of Six Sigma with C-K theory.

Originality/value

This is the first paper that proposes an integration methodology of Six Sigma with C-K theory to enhance the innovation capability to achieve the OPEX.

Empirical analysis of Six Sigma project capability deficiency and its impact on project success

Purpose

The purpose of this paper is to understand the deficiencies in Six Sigma project capability and empirically validating its impact on project success.

Design/methodology/approach

Deficiencies are identified from literature focusing on Six Sigma challenges or barriers. The study used a survey approach by circulating questionnaires to 400 Six Sigma professionals from 40 multinational organisations. The conceptual model is composed of 16 items measuring five constructs for hypothesis testing. Furthermore, structural equation modelling was used to identify the relationship between Six Sigma project capability deficiency and project success.

Findings

The findings of the study suggest that inadequate top management support, inadequate resources and change management and inadequate quality maturity form Six Sigma project capability deficiency and affect project success.

Research limitations/implications

The study uses resource-based view to understand the deficiencies in Six Sigma project capability and their impact on project success. The study confirms that organisational capabilities in implementing Six Sigma affect the success of the projects.

Practical implications

The results of this study reveal that inadequate top management support, inadequate quality maturity of the organisation and inadequate resources and change management result into a deficiency in Six Sigma project capability. Quality managers in manufacturing and service organisations should attempt to improve these capabilities to achieve competitive advantage.

Originality/value

The study contributes to the literature by exploring the capability outlook of Six Sigma. The study attempts to fill the gap in Six Sigma literature by providing a structural model for understanding Six Sigma project capability deficiency and its impact on Six Sigma project success.

Analyzing Lean Six Sigma enablers: a hybrid ISM-fuzzy MICMAC approach

Purpose

The purpose of this paper is to identify Lean Six Sigma enablers (LSSEs) and analyse the interaction among the enablers via a hierarchical model developed by employing interpretive structural modelling (ISM) and determine the driving and dependence power of enablers through fuzzy MICMAC (Matriced’ Impacts Croise´s Multiplication Applique´ea´un Classement) analysis.

Design/methodology/approach

An expert group of industry professionals and academicians is consulted at the initial stage as an input for ISM methodology to explore the paired relationship among LSSEs for each parameter of Lean Six Sigma (LSS) implementation. The outcome of ISM is further utilized by fuzzy MICMAC analysis to discover the enablers that are strong drivers and highly dependent. Fuzzy set is included in MICMAC analysis in order to obtain more precise output and effective model.

Findings

In total, 20 key enablers are identified through a literature review and expert opinion that emerged as the most significant factors towards LSS implementation. The identified enablers are portrayed into a structural form representing as input and output variables. Later, the driving and the dependence power of each enabler is presented in cluster form.

Research limitations/implications

The paired relationships among LSSEs are obtained through the interpretation made by the experts. The judgments of experts are subjective and may be biased; as difference in expert opinion may influence the final outcome. Conducting a large-scale survey may provide a better catch for interactions of LSSEs.

Practical implications

This study provides strong practical implications for researchers as well as industry practitioners. The industry professionals must deliberately focus on the identified LSSEs more conservatively during LSS implementation and the top management should plan strategically to avoid any implementation failure.

Originality/value

The present study identifies 20 crucial enablers of integrated LSS and presents them in a hierarchical form which will be beneficial for researchers and practitioners. The interactions among the enablers shown in cluster form will help in better execution of LSS.