J. Muraliraj, Suhaiza Zailani, S. Kuppusamy and C. Santha
Literature reviews are a pervasive aspect in research. An ever mounting field such as Lean Six Sigma requires a perpetual touch on the subject to accentuate insights that can be…
Abstract
Purpose
Literature reviews are a pervasive aspect in research. An ever mounting field such as Lean Six Sigma requires a perpetual touch on the subject to accentuate insights that can be researched about. The purpose of this paper is to address the published literatures in the field of Lean Six Sigma through multiple criterion for an enhanced understanding of the subject matter through summarizing its current trends, uncovering existing literature gaps and revealing opportunities for future research in the field.
Design/methodology/approach
The literature review on Lean Six Sigma field spans around 17 years that includes peer-reviewed journals from management, business, engineering, healthcare, manufacturing, military among the many disciplines. The study uses a content analysis approach in which several dimensions of the literature were analysed: purpose or focus of study, years of publication, journal name or publications, methodologies, theories used, country of study, industry sub-sectors, active authors in the field, critical success factors, barriers and challenges and the most contribution of Lean Six Sigma papers by universities.
Findings
Eleven important findings from the analysis were summarized among them; the field of Lean Six Sigma had begun to grow significantly since the new millennium particularly after the 2004-2007 or 2008 period; standalone concepts of Lean and Six Sigma are highly researched compared to the integrated concepts; large proportion of perspective, conceptual and descriptive based studies; lack of empirical validity on the fusion between Lean and Six Sigma; lack of theoretical based studies, etc.
Research limitations/implications
The study is limited to 102 journals in commonly searched databases in the subject matter which produced 261 journal papers. This study seeks to broaden the summary of studies done under the keyword “Lean Six Sigma”.
Originality/value
The review analysis uses a content analysis approach in search of valuable gaps in existing research. The study found 261 papers from 102 journals that were published over the past seventeen years (2000-2016). This paper provides scholars, practitioners and managers with insights on the present trends and focus of Lean Six Sigma in addition to what else are lacking in the subject matter, which could pave the way for future research and practical endeavours.
Details
Keywords
J. Muraliraj, S. Kuppusamy, Suhaiza Zailani and C. Santha
The purpose of this paper is to explore how Lean and Six Sigma’s distinctive practices relate to potential absorptive capacity (PACAP) and realized absorptive capacity (RACAP)…
Abstract
Purpose
The purpose of this paper is to explore how Lean and Six Sigma’s distinctive practices relate to potential absorptive capacity (PACAP) and realized absorptive capacity (RACAP). The paper seeks to understand which of the practices in Lean Six Sigma are needed to manage absorptive capacity systematically.
Design/methodology/approach
Partial least square based structural equation modeling (PLS-SEM) was used to test the theoretical model drawing on a sample of 125 manufacturing organizations in Malaysia. In addition to examining direct effects, the study also examines indirect effects using bootstrapping method to identify possible mediation effects proposed in the model.
Findings
The results explain that Lean’s social practices (LSP), Six Sigma’s roles structure (RS) and structured improvement procedure (SIP) positively influence potential absorptive capacity (PACAP). Meanwhile LSP, RS and focus on metrics (FOM) positively influence realized absorptive capacity (RACAP). SIP was found to influence RACAP through PACAP. The analysis reveals the combination of Lean Six Sigma practices that are required in managing PACAP and RACAP differentially.
Research limitations/implications
The study is only confined to manufacturing industries in Peninsular Malaysia. Data collected were cross-sectional in nature. The application of Lean Six Sigma and how it influences absorptive capacity may get sturdier across time, and this may change the effect toward sustainability of firm’s competitive advantage. A longitudinal study may be useful in that context. The study also makes specific recommendations for future research.
Practical implications
The results of this study can be used by Lean Six Sigma practitioners to prioritize the implementation of Lean Six Sigma practices to develop absorptive capacity of the organization through PACAP and RACAP, which needs to be managed differentially as they exert differential outcomes. This would enable organizations to tactfully navigate and balance between PACAP and RACAP in accordance to business strategies and market conditions.
Originality/value
Absorptive capacity in Lean and Six Sigma context has largely been studied as a unidimensional construct or used as a grounding theoretical support. Therefore, understanding the multidimensionality through PACAP and RACAP provide insights on how to enhance and maneuver absorptive capacity through Lean Six Sigma systematically. The findings may pave the way for future research in enhancing the current knowledge threshold in Lean Six Sigma.
Details
Keywords
Choon Ling Sim, Zeyun Li, Francis Chuah, Yi Jin Lim and Kit Yeng Sin
With the growing pressure to gain optimum level of quality and speed, Lean Six Sigma (LSS) practices have drawn considerable attention as a viable alternative for process…
Abstract
Purpose
With the growing pressure to gain optimum level of quality and speed, Lean Six Sigma (LSS) practices have drawn considerable attention as a viable alternative for process improvement. However, previous studies revealed that there is very little systematic and rigorous research to validate the claims. In this regard, this paper aims to empirically examine the effect of LSS practices on quality performance in the medical device manufacturing industry.
Design/methodology/approach
For this study, partial least square–based structural equation modeling (PLS-SEM) was used to empirically examine the effect of LSS practices on quality performance in Malaysian medical device manufacturing industry.
Findings
The findings of this paper revealed that LSS practices have a significant and positive effect on quality performance in the medical device manufacturing industry.
Practical implications
This paper will serve as a valuable implication for industry practitioners in providing them with a clearer managerial direction to exploit the strength of LSS practices to achieve company’s quality goals. Moreover, this study will serve as a basis for future LSS scholars, providing them with valuable insights and directions for future research.
Originality/value
This paper develops a conceptual LSS framework that captures the integrated nature of two methodologies and provides empirical evidence that supports the positive influence of LSS practices on quality performance; hence, it contributes to the growing body of LSS literature in both theoretical and empirical sense.
Details
Keywords
Mohamed Alblooshi, Mohammad Shamsuzzaman, Michael Boon Chong Khoo, Abdur Rahim and Salah Haridy
The purpose of this paper is to identify, present and categorise the main requirements, challenges and impacts of Lean Six Sigma (LSS) applications. Emphasis is given to the soft…
Abstract
Purpose
The purpose of this paper is to identify, present and categorise the main requirements, challenges and impacts of Lean Six Sigma (LSS) applications. Emphasis is given to the soft impacts of LSS applications, which are intangible in nature and difficult to quantify and measure, highlighting the most frequently cited ones.
Design/methodology/approach
A qualitative synthesis of the studies using the narrative synthesis approach is adopted to descriptively summarise and categorise the requirements, challenges and impacts of LSS applications. The studies were searched by using the following keywords: “LSS applications,” “LSS requirements,” “LSS challenges” and “LSS impacts” in almost all major electronic databases such as Emerald, Taylor and Francis, ScienceDirect and Wiley. A total of 116 articles published between 2007 and 2017 in 41 academic journals were collected and reviewed. Consideration was also given to a number of substantial publications in 2006, 2018 and 2019.
Findings
In addition to its process efficiency and financial impacts, LSS was found to have another impact category related to individual and organisational behaviours. Management commitment, training and organisational culture were concluded to be amongst the most important and required categories for successful LSS applications. It was also found that the lack of awareness of LSS tools and benefits and the lack of change management and resistance to change were amongst the most cited categories of implementation challenges.
Research limitations/implications
The studies published between 2007 and 2017 are mainly considered in this paper. It is believed that 10-year publication period considered in this research is sufficient to study the evolution, benefits, limitations and future trends of a particular research topic. However, the exclusion criteria used in the search process with respect to the articles’ year of publication and search terms and keywords may limit the generalisation of the research findings. In addition, the qualitative nature of this research study and the lack of empirical data to support its findings is another limitation that future research should consider.
Practical implications
This research paper may serve as a valuable source of information for LSS researchers as it will provide them with useful and new insights and directions for further research in LSS. It will also increase the awareness of LSS practitioners about the kind of impact LSS has, and therefore, achieve a better utilisation of its tools by ensuring availability of application requirements and overcoming application challenges.
Originality/value
This study differs from previous research studies as it focusses attention on the soft impacts of LSS applications and highlights them. The study identifies and prioritises LSS application impacts, requirements and challenges. The study on these aspects was found to be limited and lacking in previous research studies.
Details
Keywords
This paper aims to conduct an inclusive bibliometric review of the International Journal of Lean Six Sigma (IJLSS) to elucidate the scholarly landscape, growth trends, impact…
Abstract
Purpose
This paper aims to conduct an inclusive bibliometric review of the International Journal of Lean Six Sigma (IJLSS) to elucidate the scholarly landscape, growth trends, impact, mappings, couplings, networking and thematic evolution within the field of Lean Six Sigma (LSS) research.
Design/methodology/approach
Using advanced bibliometric techniques, including network analysis and clustering, this study examines the publication output of IJLSS since its inception in 2010. The analysis focuses on identifying key contributors, mapping collaborative networks, tracing thematic evolution and exploring emerging research trends. The study is executed as per the proposed easy-to-understand methodology, containing well-structured nine segments hitting various critical-bibliometrics of IJLSS along with their respective implications.
Findings
The review reveals substantial growth in the publication output of IJLSS, with India emerging as a prominent contributor. Keywords such as “Lean”, “Six Sigma”, “Quality Management”, “Operational Excellence”, “Supply Chain Management”, “Industry 4.0” and “Sustainability” emerge as central themes, reflecting the journal’s focus on process improvement methodologies along with corresponding case studies. Collaborative networks among authors and countries are robust, indicating the global reach of LSS scholarship. Emerging research trends highlight areas of potential future exploration within the field.
Research limitations/implications
Limitations of this study include the reliance on bibliometric data and the exclusion of nonindexed sources. However, the findings offer valuable insights into the scholarly landscape of IJLSS, providing researchers and practitioners with a comprehensive overview of LSS research inclinations and developments.
Originality/value
This paper contributes to the literature by providing a detailed analysis of LSS research published in IJLSS through a unique approach and future directions. The study adds to existing knowledge by mapping collaborative networks, tracing thematic couplings and identifying emerging research clusters within the ever evolving domain of LSS.
Details
Keywords
Neeraj Yadav, Ravi Shankar and Surya Prakash Singh
Critical success factors (CSF) for lean six sigma (LSS) using quality 4.0 are not researched so far. This study aims to bridge this gap. It also validates CSF already identified…
Abstract
Purpose
Critical success factors (CSF) for lean six sigma (LSS) using quality 4.0 are not researched so far. This study aims to bridge this gap. It also validates CSF already identified for LSS under conventional technologies.
Design methodology approach
Empirical research using the questionnaire method is conducted. Construct of the questionnaire is checked using Cronbach’s alpha and responses received are analysed using t-test and exploratory factor analysis.
Findings
In total, 20 factors are evaluated for LSS success. It includes 7 factors related to quality 4.0 technologies and 13 related to the conventional set-up. All 7 quality 4.0 related factors were found critical; whereas, under traditional set-up, 11 factors out of 13 were found critical.
Practical implications
The study will help enterprises in the fast and effective adoption of quality 4.0 and seamless integration with LSS. The post-Covid-19 business scenario is expected to be information technology focussed. The findings of this study will be useful in these circumstances. Consultants and practitioners can prioritise their efforts based on newly identified CSF. The new revelation about CSF for LSS in quality 4.0 enriches theory as well.
Social implications
Developing skills based on newly identified CSF will help people in remaining employable in the era of automation, robotics and artificial intelligence which is otherwise ill-famed for destroying jobs.
Originality value
CSF for LSS using quality 4.0 is a new contribution. It differentiates CSF established earlier for conventional technologies. Moreover, many CSF are common for LSS and industry 4.0, therefore this study will also help in smoother adoption of industry 4.0/quality 4.0 in organisations.
Details
Keywords
Godson A. Tetteh, Kwasi Amoako-Gyampah and Amoako Kwarteng
Several research studies on Lean Six Sigma (LSS) have been done using the survey methodology. However, the use of surveys often relies on the measurement of variables, which…
Abstract
Purpose
Several research studies on Lean Six Sigma (LSS) have been done using the survey methodology. However, the use of surveys often relies on the measurement of variables, which cannot be directly observed, with attendant measurement errors. The purpose of this study is to develop a methodological framework consisting of a combination of four tools for identifying and assessing measurement error during survey research.
Design/methodology/approach
This paper evaluated the viability of the framework through an experimental study on the assessment of project management success in a developing country environment. The research design combined a control group, pretest and post-test measurements with structural equation modeling that enabled the assessment of differences between honest and fake survey responses. This paper tested for common method variance (CMV) using the chi-square test for the difference between unconstrained and fully constrained models.
Findings
The CMV results confirmed that there was significant shared variance among the different measures allowing us to distinguish between trait and faking responses and ascertain how much of the observed process measurement is because of measurement system variation as opposed to variation arising from the study’s constructs.
Research limitations/implications
The study was conducted in one country, and hence, the results may not be generalizable.
Originality/value
Measurement error during survey research, if not properly addressed, can lead to incorrect conclusions that can harm theory development. It can also lead to inappropriate recommendations for practicing managers. This study provides findings from a framework developed and assessed in a LSS project environment for identifying faking responses. This paper provides a robust framework consisting of four tools that provide guidelines on distinguishing between fake and trait responses. This tool should be of great value to researchers.
Details
Keywords
Paula de Santi Louzada, Tiago F.A.C. Sigahi, Gustavo Hermínio Salati Marcondes de Moraes, Izabela Simon Rampasso, Rosley Anholon, Jiju Antony and Elizabeth A. Cudney
This study aims to present an overview and analyze the Lean Six Sigma Black Belt (LSSBB) certifications offered by institutions operating in Brazil.
Abstract
Purpose
This study aims to present an overview and analyze the Lean Six Sigma Black Belt (LSSBB) certifications offered by institutions operating in Brazil.
Design/methodology/approach
This research analyzed LSSBB certification courses offered by 48 institutions in Brazil by comparing the syllabi of the classes to the reference model proposed by the American Society for Quality (ASQ) in the Six Sigma Black Belt Body of Knowledge. This study employed the content analysis technique and hierarchical cluster analysis to analyze the data.
Findings
The results revealed a lack of standardization in the content of Lean Six Sigma (LSS) training in Brazil. 100% of the LSSBB courses analyzed covered four of the 108 techniques recommended by the ASQ Body of Knowledge (i.e. data types, measurement scales, sampling, and data collection plans and methods). In contrast, more than 75% of the courses covered all techniques related to the macro areas of organization-wide planning and deployment, organizational process management and measures, measure, and improve. The major shortcoming of LSS training is related to the macro area Design for Six Sigma framework and methodologies. LSS training is offered in a highly concentrated area in Brazil, the wealthiest region, where universities play a crucial role in disseminating LSS.
Originality/value
The literature lacks studies that critically examine LSS certification courses. There is little research on LSS in Brazil and there are no studies on LSS training in this country.
Details
Keywords
Mohammad Abdul Latif and Jan Vang
Top management commitment (TMC) and prosocial voice behaviour in Lean teams are vital for the successful Lean implementation. This study aims to investigate how TMC influences…
Abstract
Purpose
Top management commitment (TMC) and prosocial voice behaviour in Lean teams are vital for the successful Lean implementation. This study aims to investigate how TMC influences Lean team members’ prosocial voice behaviour and how such changed voice behaviour affects the outcome of Lean implementations.
Design/methodology/approach
The authors have used a qualitative research methodology to examine six dimensions of TMC (communication, involvement, support, empowerment, encouragement and monitoring) in two ready-made garment (RMG) factories in Bangladesh. Operational performance was measured by efficiency, quality, value stream mapping, single-minute exchange dies and 5S scores. Occupational Health and Safety (OHS) was assessed by acceptable head and back positions, machine safety, use of masks and housekeeping.
Findings
The findings reveal that TMC influences Lean team members' voice behaviour positively and, thereby, company's performance. Six dimensions of TMC are all critical for mobilizing prosocial voice, which then improves productivity, OHS and enhancing employee capacity and job satisfaction.
Research limitations/implications
This research involved two sewing lines in two RMG factories in Bangladesh. Cross-sector and large-scale international quantitative research is also needed.
Practical implications
This research shows how TMC and Lean problem-solving teams can mobilize employee voice.
Originality/value
Employee voice is a central issue in the implementation of Lean. To the best of the author’s knowledge, for the first time, the authors show how the six dimensions of TMC influence Lean team members’ voice behaviour in the workplace and thereby how prosocial voice affects team performance.
Details
Keywords
Aqeel Ahmed, Sanjay Mathrani and Nihal Jayamaha
The aim of this paper is to explore the implementation of an integrated lean and ISO 14001 approach in meat industry for environmental performance and examine a proposed…
Abstract
Purpose
The aim of this paper is to explore the implementation of an integrated lean and ISO 14001 approach in meat industry for environmental performance and examine a proposed conceptual framework by capturing insights from lean and ISO 14001 experts in New Zealand (NZ).
Design/methodology/approach
Semi-structured interviews have been conducted with a group of consultants (lean and ISO 14001) to evaluate the suitability of an integrated lean and ISO 14001 approach in the meat industry for environmental performance. A conceptual framework from literature has guided this study leading to its further development based on the empirical evidence collected.
Findings
Findings have illustrated a synergistic positive impact of lean and ISO 14001 implementation as an integrated approach for sustaining environmental performance in the meat industry. A joint implementation program provides more clarity in aligning ISO 14001 operational procedures with lean tools and techniques for an enhanced environmental performance outcome.
Practical implications
The application of an integrated lean and ISO 14001 framework is proposed in this paper, which can help industry practitioners and academia in developing a joint implementation strategy and conducting future research.
Originality/value
To the best of the author’s knowledge, this study is the first to assess the effective implementation of lean and ISO 14001 as an integrated approach in the NZ meat industry.