A novel approach to lean six sigma project management: a conceptual framework and empirical application

Abstract The recent evolution of Lean Six Sigma (LSS) presents a potent combination of the speed of Lean and the robustness of Six Sigma. Literature shows significant application of DMAIC (Define-Measure-Analyse-Improve-Control) framework in LSS projects. Many studies suggest that LSS makes a positive contribution towards the effectiveness of organisations. However, a few studies also suggest that organisations find DMAIC projects problematic, and in many cases ineffective. We investigate and resolve this paradox by conceptualising a novel LSS framework, and further test it for practical implications. A four-phase methodology is used. In phase-1, relevant data is pooled from multiple sources including the literature, semi-structured interviews and questionnaire-based survey in the scope of the manufacturing sector. The pooled data is classified and analysed in Phase-2. Phase-3 focused on development of the conceptual framework, and Phase-4 aimed to test the conceptual framework in select manufacturing firms in real-world environment. This study reveals focused gaps and shortcomings of the DMAIC framework for LSS project management. Secondly, we propose a novel approach to LSS project management by conceptualising ‘SDMMAICS’ framework. Thirdly, we validated the conceptual framework in real-world. Finally, the practical implications were discussed to add value to both researchers and practitioners.

[1]  G. Stasser,et al.  Pooling of Unshared Information in Group Decision Making: Biased Information Sampling During Discussion , 1985 .

[2]  Nick Rich,et al.  The seven value stream mapping tools , 1997 .

[3]  V. M. Rao Tummala,et al.  A quality control and improvement system based on the total control methodology (TCM) , 1998 .

[4]  Phil Catherwood.  What's different about Six Sigma? , 2002 .

[5]  Jean Sandra Baulcomb.  Management of change through force field analysis. , 2003, Journal of nursing management.

[6]  David Blane,et al.  The Lifegrid Method of Collecting Retrospective Information from People at Older Ages , 2003 .

[7]  Greg A. Larsen.  Measurement System Analysis in a Production Environment with Multiple Test Parameters , 2003 .

[8]  John S. Oakland,et al.  Tqm: Text with Cases , 2003 .

[9]  Albert Johnson,et al.  Managers at Work: How Six Sigma Improves R&D , 2003 .

[10]  Nihar Ranjan Senapati,et al.  Six Sigma: myths and realities , 2004 .

[11]  Michael Lewis,et al.  The two worlds of operations management research and practice: Can they meet, should they meet? , 2004 .

[12]  Gary Pickrell,et al.  Lean Six Sigma implementation case studies , 2005 .

[13]  E. V. Gijo,et al.  Six Sigma implementation – Hurdles and more hurdles , 2005 .

[14]  Elisabeth Viles,et al.  Six Sigma and its link to TQM, BPR, lean and the learning organisation , 2005 .

[15]  Daniel T Jones,et al.  Lean consumption. , 2005, Harvard business review.

[16]  John P. S. Verver,et al.  Lean Six Sigma in Healthcare , 2006, Journal for healthcare quality : official publication of the National Association for Healthcare Quality.

[17]  S. G. Deshmukh,et al.  Implementing Six Sigma in service sector using AHP and Alderfer's motivational model - a case of educational services , 2006 .

[18]  Tony Bendell,et al.  A review and comparison of six sigma and the lean organisations , 2006 .

[19]  Manoj Kumar Tiwari,et al.  Implementing the Lean Sigma framework in an Indian SME: a case study , 2006 .

[20]  William C. Parr.  Making Six Sigma Last , 2006 .

[21]  Vijay Shanmugam.  Six Sigma Cup: Establishing Ground Rules for Successful Six Sigma Deployment , 2007 .

[22]  Govindarajan Ramu.  Six Sigma Project Assignment: Know Your Black Belts , 2007 .

[23]  Andrew Thomas,et al.  Lean Six Sigma: an integrated strategy for manufacturing sustainability , 2008 .

[24]  Jiju Antony,et al.  Can Six Sigma be effectively implemented in SMEs , 2008 .

[25]  Dag Näslund,et al.  Lean, six sigma and lean sigma: fads or real process improvement methods? , 2008, Bus. Process. Manag. J..

[26]  Rachna Shah,et al.  In pursuit of implementation patterns: the context of Lean and Six Sigma , 2008 .

[27]  Jürgen P. Wagner,et al.  SELECTION OF QUALITY IMPROVEMENT INITIATIVES: AN INITIAL CONCEPTUAL MODEL , 2009 .

[28]  L. Fredendall,et al.  Enhancing Six Sigma Implementation Through Human Resource Management , 2009 .

[29]  Suresh Garg,et al.  Lean implementation and its benefits to production industry , 2010 .

[30]  Erick C. Jones,et al.  A framework for effective Six Sigma implementation , 2010 .

[31]  Jiju Antony,et al.  Lean six sigma in a call centre : a case study , 2010 .

[32]  Trevor A Spedding,et al.  The evolution of lean Six Sigma , 2010 .

[33]  Tom Page.  Achieving Manufacturing Excelence by Applying LSSF Model A Lean Six Sigma Framework , 2010 .

[34]  Catarina Delgado,et al.  The implementation of lean Six Sigma in financial services organizations , 2010 .

[35]  Ronald D. Snee,et al.  Lean Six Sigma – getting better all the time , 2010 .

[36]  Marcia S. Hagen.  Black Belt Coaching and Project Outcomes: An Empirical Investigation , 2010 .

[37]  Elizabeth A. Cudney,et al.  A comparative analysis of integrating lean concepts into supply chain management in manufacturing and service industries , 2011 .

[38]  David C. Yen,et al.  Improving the efficiency of IT help-desk service by Six Sigma management methodology (DMAIC) – a case study of C company , 2011 .

[39]  Jennifer A. Farris,et al.  A Multilevel Framework for Lean Product Development System Design , 2011 .

[40]  S. Vinodh,et al.  Implementing lean sigma framework in an Indian automotive valves manufacturing organisation: a case study , 2011 .

[41]  Eric Rebentisch,et al.  A Framework for Organizing Lean Product Development , 2011 .

[42]  António Grilo,et al.  A framework for evaluating lean implementation appropriateness , 2011, 2011 IEEE International Conference on Industrial Engineering and Engineering Management.

[43]  Matthew Franchetti,et al.  Continuous improvement and value stream analysis through the lean DMAIC Six Sigma approach: a manufacturing case study from Ohio, USA , 2011 .

[44]  Manoj Kumar Tiwari,et al.  Six Sigma implementation framework for SMEs – a roadmap to manage and sustain the change , 2011 .

[45]  N. Vijay Mohan,et al.  QUARNEWSS: a model for applying Six Sigma framework to achieve continuous quality and reliability improvement in new product development , 2011 .

[46]  Amrik S. Sohal,et al.  A conceptual model for the successful deployment of Lean Six Sigma , 2012 .

[47]  A. Chiarini.  Risk management and cost reduction of cancer drugs using Lean Six Sigma tools , 2012 .

[48]  Satya S. Chakravorty,et al.  Lean Six Sigma (LSS): an implementation experience , 2012 .

[49]  Ruben Pinedo-Cuenca,et al.  Linking Six Sigma's critical success/hindering factors and organizational change (development) , 2012 .

[50]  John Maleyeff,et al.  The continuing evolution of Lean Six Sigma , 2012 .

[51]  Chen-Yang Cheng,et al.  Implementation of the Lean Six Sigma framework in non-profit organisations: A case study , 2012 .

[52]  N. Nordin,et al.  A framework for organisational change management in lean manufacturing implementation , 2012 .

[53]  Jiju Antony,et al.  PROOF COVER SHEET , 2011 .

[54]  Alexandros G. Psychogios,et al.  Towards an integrated framework for Lean Six Sigma application: Lessons from the airline industry , 2012 .

[55]  Jeroen de Mast,et al.  An analysis of the Six Sigma DMAIC method from the perspective of problem solving , 2012 .

[56]  Vijaya Sunder.  Synergies of Lean Six Sigma , 2013 .

[57]  V. Sunder.  Six Sigma - A Strategy for Increasing Employee Engagement , 2013 .

[58]  Andrea Chiarini,et al.  Implementing Lean Six Sigma in healthcare: issues from Italy , 2013 .

[59]  Prakash Pralhad Chaudhari.  Implementing Lean Six Sigma , 2013 .

[60]  Sami Kara,et al.  Selection of Lean and Six Sigma projects in industry , 2013 .

[61]  Jiju Antony,et al.  Critical failure factors of Lean Six Sigma: a systematic literature review , 2014 .

[62]  S. Vinodh,et al.  Implementing lean sigma in an Indian rotary switches manufacturing organisation , 2014 .

[63]  Thong Ngee Goh,et al.  Comprehensive Six Sigma application: a case study , 2014 .

[64]  Maneesh Kumar,et al.  Absorbing new knowledge in small and medium-sized enterprises: A multiple case analysis of Six Sigma , 2014 .

[65]  Sanjay Bhasin.  Lean Management Beyond Manufacturing , 2015 .

[66]  Jiju Antony,et al.  Six-sigma for improving Top-Box Customer Satisfaction score for a banking call centre , 2015 .

[67]  Mark Pagell,et al.  Making a meaningful contribution to theory , 2015 .

[68]  Jiju Antony,et al.  A systematic review of Lean Six Sigma for the manufacturing industry , 2015, Bus. Process. Manag. J..

[69]  S. R. Devadasan,et al.  Enhancement of sigma level in the manufacturing of furnace nozzle through DMAIC approach of Six Sigma: a case study , 2016 .

[70]  M. Kreye.  Employee motivation in product-service system providers , 2016 .

[71]  M. Sunder.  Lean six sigma project management – a stakeholder management perspective , 2016 .

[72]  V Raja Sreedharan,et al.  A Systematic Literature Review of Lean Six Sigma in Different Industries , 2016 .

[73]  A. Woodside,et al.  Making tough decisions competently: Assessing the value of product portfolio planning methods, devil’s advocacy, group discussion, weighting priorities, and evidenced-based information , 2016 .

[74]  M. Sunder,et al.  Lean Six Sigma in higher education institutions , 2016 .

[75]  M Vijaya Sunder,et al.  Rejects reduction in a retail bank using Lean Six Sigma , 2016 .

[76]  J. Guthrie,et al.  Group rewards, group composition and information sharing: A motivated information processing perspective , 2016 .

[77]  Maneesh Kumar,et al.  Implementation of continuous improvement based on Lean Six Sigma in small- and medium-sized enterprises , 2016 .

[78]  S. Vinodh,et al.  Implementation of Lean Six Sigma framework with environmental considerations in an Indian automotive component manufacturing firm: a case study , 2017 .

[79]  Jiju Antony,et al.  Failure of Continuous Improvement initiatives in manufacturing environments: a systematic review of the evidence , 2017 .

[80]  S. Srivatsa Srinivas,et al.  A review of the quality evolution in various organisations , 2017 .

[81]  Nitin Seth,et al.  Application of value stream mapping (VSM) for lean and cycle time reduction in complex production environments: a case study , 2017 .

[82]  L. S. Ganesh,et al.  A morphological analysis of research literature on Lean Six Sigma for services , 2018 .

[83]  R. Parameshwaran,et al.  Fuzzy integrated QFD, FMEA framework for the selection of lean tools in a manufacturing organisation , 2018 .

[84]  Jiju Antony,et al.  Assessment of critical failure factors (CFFs) of Lean Six Sigma in real life scenario , 2018, Benchmarking: An International Journal.

[85]  M. Shamsuzzaman,et al.  Using Lean Six Sigma to improve mobile order fulfilment process in a telecom service sector , 2018 .