Combining Lean and Six Sigma in the context of Systems Engineering design

Abstract

Purpose

The purpose of this paper is to present a combined framework for system design using Six Sigma and Lean concepts. Systems Engineering has evolved independently and there are numerous tools and techniques available to address issues that may arise in the design of systems. In the context of systems design, the application of Six Sigma and Lean concepts results in a flexible and adaptable framework. A combined framework is presented here that allows better visualization of the system-level components and their interactions at parametric level, and it also illuminates gaps that make way for continuous improvement. The Deming’s Plan-Do-Check-Act is the basis of this framework. Three case studies are presented to evaluate the application of this framework in the context of Systems Engineering design. The paper concludes with a summary of advantages of using a combined framework, its limitations and scope for future work.

Design/methodology/approach

Six Sigma, Lean and Systems Engineering approaches combined into a framework for collaborative product development.

Findings

The present framework is not rigid and does not attempt to force fit any tools or concepts. The framework is generic and allows flexibility through a plug and play type of implementation. This is important, as engineering change needs vary constantly to meet consumer demands. Therefore, it is important to engrain flexibility in the development of a foundational framework for design-encapsulating improvements and innovation. From a sustainability perspective, it is important to develop techniques that drive rationality in the decisions, especially during tradeoffs and conflicts.

Research limitations/implications

Scalability of the approach for large systems where complex interactions exist. Besides, the application of negotiation techniques for more than three persons poses a challenge from a mathematical context. Future research should address these in the context of systems design using Six Sigma and Lean techniques.

Practical implications

This paper provides a flexible framework for combining the three techniques based on Six Sigma, Lean and Systems Engineering.

Social implications

This paper will influence the construction of agent-based systems, particularly the ones using the Habermas’s theory of social action as the basis for product development.

Originality/value

This paper has not been published in any other journal or conference.

Citation

Sreeram, T. and Thondiyath, A. (2015), "Combining Lean and Six Sigma in the context of Systems Engineering design", International Journal of Lean Six Sigma, Vol. 6 No. 4, pp. 290-312. https://doi.org/10.1108/IJLSS-07-2014-0022