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Article
Publication date: 27 June 2023

Sandeep Kumar, Vikas Swarnakar, Rakesh Kumar Phanden, Dinesh Khanduja and Ayon Chakraborty

The purpose of this study is to present the systematic literature review (SLR) on Lean Six Sigma (LSS) by exploring the state of the art on growth of literature on LSS within the…

572

Abstract

Purpose

The purpose of this study is to present the systematic literature review (SLR) on Lean Six Sigma (LSS) by exploring the state of the art on growth of literature on LSS within the manufacturing sector, critical factors to implement LSS, the role of LSS in the manufacturing sector from an implementation and sustainability viewpoint and Industry 4.0 viewpoints while highlighting the research gaps.

Design/methodology/approach

An SLR of 2,876 published articles extracted from Scopus, WoS, Emerald Insight, IEEE Xplore, Taylor & Francis, Springer and Inderscience databases was carried out following the protocol of systematic review. In total, 154 articles published in different journals over the past 10 years were selected for quantitative and qualitative analysis which revealed a number of research gaps.

Findings

The findings of the SLR revealed the growth of literature on LSS within the manufacturing sector. The review also highlighted the most cited critical success factors, critical failure factors, performance indicators and associated tools and techniques applied during LSS implementation. The review also focused on studies related to LSS and sustainability viewpoint and LSS and Industry 4.0 viewpoints.

Practical implications

The findings of this SLR can help senior managers, practitioners and researchers to understand the current developments and future requirements to adopt LSS in manufacturing sectors from sustainability and Industry 4.0 viewpoints.

Originality/value

Academic publications in the context of the role of LSS in various research streams are sparse, and to the best of the authors’ knowledge, this paper is one of the first SLRs which explore current developments and future requirements to implement LSS from sustainability and Industry 4.0 perspective.

Details

The TQM Journal, vol. 36 no. 7
Type: Research Article
ISSN: 1754-2731

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Article
Publication date: 5 March 2018

Ben Ruben R., Vinodh S. and Asokan P.

The purpose of this study is to prioritize and analyze the barriers that affect Lean Six Sigma (LSS) adoption with environmental considerations.

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Abstract

Purpose

The purpose of this study is to prioritize and analyze the barriers that affect Lean Six Sigma (LSS) adoption with environmental considerations.

Design/methodology/approach

To 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.

Findings

Based 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 implications

The 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/value

The 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.

Details

International Journal of Lean Six Sigma, vol. 9 no. 1
Type: Research Article
ISSN: 2040-4166

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Article
Publication date: 14 February 2020

Ben Ruben R., S. Vinodh and Asokan P.

The study aims to describe the development of a structural measurement model using structural equation modeling technique to validate the association that exists between Lean Six…

856

Abstract

Purpose

The study aims to describe the development of a structural measurement model using structural equation modeling technique to validate the association that exists between Lean Six Sigma (LSS) and sustainable manufacturing strategies.

Design/methodology/approach

Both LSS and sustainable manufacturing aim at improving the firm’s business competitiveness which forms a strategic link that benefits the manufacturing organizations. The study aims to investigate the relationship among constructs that leads to operational excellence while deploying LSS and sustainable manufacturing strategies in organizations.

Findings

Empirical data needed for the study are collected from experts belonging to various industries that are implementing both LSS and sustainable manufacturing practices. Later statistical estimates (hypotheses) are being formulated to confirm the developed measurement model. Based on the obtained results after analysis of the structural model, the statistical estimate is either being accepted or rejected. Results of this study reveal that there exists a strong correlation between LSS and sustainable manufacturing factors that leads to organizational performance.

Research limitations/implications

Additional indicators could be included to deal with technological advancements in sustainable manufacturing.

Practical implications

The study has been done with regard to Indian automotive component manufacturing organizations scenario. Hence, the inferences derived have practical relevance.

Originality/value

The development of structural model for the Lean Six Sigma system with sustainability considerations is the original contribution of the authors.

Details

International Journal of Lean Six Sigma, vol. 11 no. 4
Type: Research Article
ISSN: 2040-4166

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Article
Publication date: 26 June 2018

Ben Ruben R., S. Vinodh and Asokan P.

The contemporary manufacturing organizations recognize the importance of lean manufacturing as a tool to eliminate wastes, streamline processes and improve value addition. On the…

1967

Abstract

Purpose

The contemporary manufacturing organizations recognize the importance of lean manufacturing as a tool to eliminate wastes, streamline processes and improve value addition. On the other hand, such organizations also focus on the development of ecofriendly products and processes. In this context, lean manufacturing concepts provide a pathway for attaining sustainable benefits. This paper aims to present the state of art review on lean and sustainable manufacturing.

Design/methodology/approach

A total of 80 research papers on lean and sustainable manufacturing from various perspectives have been reviewed and their contributions are being presented. The perspectives include origin, definition, decision-making, performance measurement, product development and application for both lean and sustainable manufacturing.

Findings

Findings from the literature prove that both lean and sustainable manufacturing systems aim at improving the organizational performance and provide both operational and sustainable benefits. Also based on the studies, it has been found that integrated lean sustainable manufacturing system can be defined as a system that creates value for the customers by eliminating wastes consistently and adopting processes that are ecofriendly, economically viable and safe for the employees to produce green products that enhance the social performance.

Research limitations/implications

The present review considers the papers on lean and sustainable manufacturing based on certain perspectives. Peer-reviewed journal articles, and books are only being considered and reviewed. Articles and information from dissertation thesis, unpublished working papers and conference proceedings were excluded. In future, the study can be enhanced by considering more such perspectives that reflect the ideology and applicability of the selected themes. The practical perspectives of lean and sustainable manufacturing and their integration are also being presented.

Originality/value

This paper presents a review of lean and sustainable manufacturing and provides insights from different perspectives. The scope for their integration is also discussed. The contributions are original.

Details

International Journal of Lean Six Sigma, vol. 10 no. 1
Type: Research Article
ISSN: 2040-4166

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Article
Publication date: 12 February 2021

Pramod Kumar, Dharmendra Singh and Jaiprakash Bhamu

The purpose of this paper is to develop and validate an extended Define-Measure-Analyze-Improve-Control (DMAIC) based framework through a case study of an Indian fasteners…

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Abstract

Purpose

The purpose of this paper is to develop and validate an extended Define-Measure-Analyze-Improve-Control (DMAIC) based framework through a case study of an Indian fasteners manufacturing organization.

Design/methodology/approach

Research methodology is established on the development of the existing DMAIC framework through an extensive literature review of 25 LSS/DMAIC based frameworks and discussions held with practitioners. This paper also depicts a case study of Indian manufacturing organization for validation of the developed framework.

Findings

The study proposed an extended DMAIC based framework for effective implementation of Lean Six Sigma (LSS) methodology. Furthermore, this framework has been implemented successfully in the Indian manufacturing organization and showed encouraging results. The in-house rejections of Nut Cylinder Head (NCH) were brought down to 966 from 2910 PPM and sigma level was improved by 0.40. The case organization has achieved significant improvements in the process capability, customer satisfaction, and cost savings of US$ 0.25 million in one financial year. Intangible benefits like improvements in employee's morale, communication, housekeeping and decision-making capabilities were also observed significantly.

Practical implications

The proposed DMAIC based framework has been implemented successfully in the Indian case organization, and the results will enable the policymakers, specifically practitioners, to strategically leverage the resources for successful implementation of the LSS in healthcare, aerospace, service sectors etc.

Originality/value

This research develops a DMAIC based framework which can be used to implement LSS effectively in different industries. Moreover, the pre (initial/introduction) and post (validation/verification) implementation phase provides the top management, an edge to think strategically into broader improvement areas.

Details

International Journal of Quality & Reliability Management, vol. 38 no. 9
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 2 February 2021

Astha Sharma, Neeraj Bhanot, Ajay Gupta and Rajeev Trehan

This study aims to utilize DMAIC methodology along with value stream mapping and other Lean Six Sigma tools in a major automobile light manufacturing industry to reduce defect…

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Abstract

Purpose

This study aims to utilize DMAIC methodology along with value stream mapping and other Lean Six Sigma tools in a major automobile light manufacturing industry to reduce defect rates and increase production capacity in their manufacturing line. The study also proposes a modified framework based on lean principles and FlexSim to identify and reduce waste in the selected industry.

Design/methodology/approach

A Lean Six Sigma modified framework has been deployed with DMAIC to reduce the defect rate and increase the production rate. Various tools like value stream mapping, brainstorming, Pareto charts, 5S, kanban, etc. have been used at different phases of DMAIC targeting wastes and inventory in the production line. Also, a simulation model has been utilized for the automobile light manufacturing industry to improve the machine utilization time with varying batch sizes.

Findings

The results of the study indicated a 53% reduction in defect rates. Thus, there would be an expected improvement in sigma value from 3.78 to 3.89 and a reduction in defects per million opportunities (DPMO) from 11,244 to 8,493. Additionally, simulation model using FlexSim was developed, and the optimum ordering batch size of raw material was obtained. It was also analyzed that idle time for various stations could be reduced by up to 30%.

Practical implications

The utilized framework helps identify defects for managers to increase production efficiency. The workers, operators and supervisors on the production line also need to be trained regularly for identifying the areas of improvement.

Originality/value

The modified Lean Six Sigma framework used in this study includes FlexSim simulation to make the framework robust, which has not been used with LSS tools in the literature studied. Also, the LSS finds very less application in the manufacturing domain, considering which this study tends to add value in existing literature taking a case of an automobile light manufacturing industry.

Details

International Journal of Productivity and Performance Management, vol. 71 no. 5
Type: Research Article
ISSN: 1741-0401

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Article
Publication date: 11 April 2023

Mahipal Singh and Rajeev Rathi

The present environmental concern has enforced manufacturing firms to re-evaluate their business practices to reduce the adverse impact on the environment with optimum production…

635

Abstract

Purpose

The present environmental concern has enforced manufacturing firms to re-evaluate their business practices to reduce the adverse impact on the environment with optimum production. Therefore, the present study aims to deal with the implementation of the environmental lean six sigma (ELSS) framework in an Indian medical equipment manufacturing industry to obtain operational and environmental sustainability.

Design/methodology/approach

The proposed ELSS framework is based on the DMAIC (Define–Measure–Analyze–ImproveControl) methodology, sustainability and lean tools. The efficacy of the developed framework is tested through a case study in an Indian medical equipment manufacturing unit.

Findings

In the case company, four major issues were reported, i.e. improper material handling, non-productive movement of men and material, poor indoor air quality and rework. The ELSS project facilitates the case organization to enhance their capacity utilization from 59.25% to 74.3%, defects per million opportunities reduce from 309,523 to 48,951.44 and indoor air quality levels decrease from 156.87 to 86.85 µgm3.

Research limitations/implications

The efficacy of the developed ELSS framework is evaluated through a case study conducted only in one Indian manufacturing environment.

Practical implications

The present study facilitates industrial managers and practitioners to achieve sustainability and process excellence through ELSS implementation. Organizations that intend to simultaneously improve operational and environmental performance can benefit from this paper as it can be used as a guide to conduct similar projects with both operational and environmental benefits.

Originality/value

This paper presents a successful implementation of the ELSS framework in the healthcare industry to achieve operational and environmental sustainability.

Details

The TQM Journal, vol. 36 no. 1
Type: Research Article
ISSN: 1754-2731

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Article
Publication date: 27 December 2022

Anand S. Patel and Kaushik M. Patel

Evidence indicates that the Indian economy has grown enormously in recent years. and Lean Six Sigma (LSS) has evolved globally as a structured business improvement strategy with…

275

Abstract

Purpose

Evidence indicates that the Indian economy has grown enormously in recent years. and Lean Six Sigma (LSS) has evolved globally as a structured business improvement strategy with diverse applicability in the last fifteen years. Therefore, this paper aims to investigate the status of LSS implementation in Indian industries using a survey research technique.

Design/methodology/approach

A survey questionnaire was devised from the literature, containing 25 questions to assess respondents’ awareness of the LSS methodology and gain insights on aspects associated with LSS adoption in Indian industries. The survey questionnaire was validated and was conducted using randomly sampled respondents from the Confederation of Indian Industries membership database. The collected data were statistically analyzed using IBM SPSS and MS Excel.

Findings

The findings attest that adopting LSS is not so encouraging and extremely poor in small- and medium-scale Indian industries. ISO 9001 emerged as a prominent quality improvement program. It is learnt that consultants play a pivotal role in bringing awareness and skills building while implementing LSS. Results endorse top management commitment and involvement, and resistance to change as leading success factors and challenges, respectively. Further, it is revealed that respondents were highly satisfied after the adoption of LSS.

Research limitations/implications

The findings of this study were derived from 183 responses and should be generalized cautiously.

Originality/value

This paper provides valuable insights on the present status covering the issues related to L:SS implementation in India. These results can motivate the managers of Indian industries for wide adoption of the LSS methodology. In addition, the findings of the paper may assist the researchers providing direction to carry out further research in LSS in the Indian context.

Details

International Journal of Lean Six Sigma, vol. 14 no. 4
Type: Research Article
ISSN: 2040-4166

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Article
Publication date: 12 July 2023

Vimal Kumar, Elizabeth A. Cudney, Ankesh Mittal, Ajay Jha, Neeraj Yadav and Ali Al Owad

New product development (NPD) is necessary for business sustenance and customer satisfaction. Six Sigma and Design for Lean Six Sigma (DLSS) efficiently employ the repetitive…

737

Abstract

Purpose

New product development (NPD) is necessary for business sustenance and customer satisfaction. Six Sigma and Design for Lean Six Sigma (DLSS) efficiently employ the repetitive stages for NPD, leading to quality performance and profitability. This study aims to map the quality performance through NPD attributes through the Lean methodology.

Design/methodology/approach

The data on NPD were collected from 267 respondents from manufacturing companies to map the relationship between Six Sigma and DLSS for NPD. Confirmatory factor analysis was employed to confirm model fit, while structural equation modeling was employed to analyze the empirical data for framework testing. The study included nine variables and fourteen hypotheses identified from the literature.

Findings

The statistical results of this study show that NPD attributes such as innovation, marketing, organization, customer, product and technology positively influence the Lean Six Sigma structured improvement process (LSSSIP) and DLSS. Moreover, integrating these attributes in Lean planning enhance quality performance. This empirical investigation's findings indicate that ten of the 14 hypotheses were supported, giving the study a strong foundation.

Research limitations/implications

The data collection was limited to northern India; therefore, the results may not be generalizable to other areas of the world.

Practical implications

NPD involves handling technical issues and factors such as cost, operational bottlenecks, economic changes, competitors' strategy and company policy. This study helps understand the various NPD parameters and their relationship to Lean, which enables an effective NPD implementation strategy.

Originality/value

The current philosophy of NPD calls for a concurrent engineering approach; therefore, the entire organization must be part of this process. This study uses the holistic framework by optimizing NPD with Lean Six Sigma (LSS) principles. The study is unique in that, to date, research does not integrate NPD attributes with the objectives of LSS to develop an efficient NPD implementation strategy.

Details

The TQM Journal, vol. 36 no. 7
Type: Research Article
ISSN: 1754-2731

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Article
Publication date: 11 March 2021

Jaivesh Gandhi, Shashank Thanki and Jitesh J. Thakkar

The Indian manufacturing sector currently contributes 16–17% to gross domestic product (GDP) and gives employment to around 12% (2014) of the country's workforce. Among the…

714

Abstract

Purpose

The Indian manufacturing sector currently contributes 16–17% to gross domestic product (GDP) and gives employment to around 12% (2014) of the country's workforce. Among the various initiatives planned under Atma Nirbhar Bharat and “Make in India”, the Indian government aims to increase the share of the manufacturing sector to country's GDP to 25% by 2025. To ensure sustainable growth of the Indian manufacturing industries in global market, successful and implementation of strategies such as lean manufacturing, green manufacturing along with six sigma are crucial. This research aims at identification and analysis of barriers to successful implementation of integrated Lean Green Six Sigma (LG&SS) strategies.

Design/methodology/approach

Based on an evaluative literature review and expert's opinion, this research identifies 18 barriers to lean, green and six sigma implementation in the manufacturing industry in India. The inter-relationships among the barriers is identified using an integrated approach of ISM (interpretive structural modelling) and Fuzzy Matrice d’Impacts Croisés Multiplication Appliquée á un Classement (MICMAC).

Findings

ISM helps to derive key managerial insights and implementation plan based on the identified inter-relationships among the barriers. Fuzzy MICMAC analysis classifies the barriers into four categories, namely, autonomous, driver, dependent and linkage to understand their relative impact on the implementation of LG&SS practices in the Indian manufacturing industry. “Lack of cooperation and mutual trust between management and employees”, “The scarcity of time and work pressure”, “lack of continuous improvement work culture” and “lack of cooperation from suppliers” that forms the top most level of the model. “Weak legislation” is a highly significant barrier to LG&SS implementation in the Indian manufacturing industries.

Practical implications

It is expected that the findings of this research will help the Indian manufacturing industry to derive a sustainable competitive advantage through an effective implementation of LG&SS practices.

Originality/value

This study can be seen as the first attempt in investigating barriers to successful implementation of lean, green and six sigma strategies in the Indian manufacturing industries using ISM and fuzzy MICMAC analysis.

Details

The TQM Journal, vol. 33 no. 8
Type: Research Article
ISSN: 1754-2731

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