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Article
Publication date: 29 July 2014

Ashok Sarkar, Arup Ranjan Mukhopadhyay and Sadhan Kumar Ghosh

The purpose of this paper is to develop a guideline of the control procedure and tools depending on dominance pattern. In Lean Six Sigma (LSS) implementation, the control phase…

Abstract

Purpose

The purpose of this paper is to develop a guideline of the control procedure and tools depending on dominance pattern. In Lean Six Sigma (LSS) implementation, the control phase plays a vital role in sustaining the gains achieved from the improvement phase. The process control schemes should be developed by studying the process dominance pattern as suggested by Juran.

Design/methodology/approach

Discussion has been made on identification of various methods with the help of a few real life examples for effective LSS implementation.

Findings

The dominance pattern helps in identifying the control mechanism. However, with the advent of new business processes, the dominance pattern needs a little bit of modification.

Research limitations/implications

The case studies mainly are from the manufacturing sector and one from the service sector, where authors have studied the control mechanism. There exists scope of future research in service sector for adequate representation.

Originality/value

The treatise provides a road map to the practitioners for an effective implementation of the control phase in LSS. It is also expected to provide the scope of future work in this direction for both researchers and practitioners.

Details

International Journal of Lean Six Sigma, vol. 5 no. 3
Type: Research Article
ISSN: 2040-4166

Keywords

Article
Publication date: 22 November 2011

Ashok Sarkar, Arup Ranjan Mukhopadhyay and Sadhan Kumar Ghosh

The purpose of this paper is to develop a criterion for selection of critical sub‐processes when all the sub‐processes cannot be taken up simultaneously for improvement. There…

1245

Abstract

Purpose

The purpose of this paper is to develop a criterion for selection of critical sub‐processes when all the sub‐processes cannot be taken up simultaneously for improvement. There exist various methods but the practitioners get utterly confused because of the existence of these multiple options. In this paper, the goal is to assist practitioners in the selection of the critical sub‐processes.

Design/methodology/approach

The authors discuss various statistical methods such as correlation and regression, simulation, basic statistics such as average, standard deviation, coefficient of variation % (C.V.%), etc. for the selection and identification of the critical sub‐processes. The strengths and weaknesses of these methods have been compared through empirical analysis based on real‐life case examples.

Findings

The stepwise regression and simulation have been found to yield identical results. However, from the perspective of application, stepwise regression has been found to be a preferred option.

Originality/value

The roadmap thus evolved for the selection of the critical sub‐processes will be of great value to the practitioner, as it will help them understand the ground reality in an unambiguous manner, resulting in a superior strategy for process improvement.

Details

International Journal of Lean Six Sigma, vol. 2 no. 4
Type: Research Article
ISSN: 2040-4166

Keywords

Article
Publication date: 31 May 2013

Shri Ashok Sarkar, Arup Ranjan Mukhopadhyay and Sadhan Kumar Ghosh

In the service sector, reduction of cycle time is one of the key issues. Among various approaches, Lean Six Sigma became very popular as it provides the organisation the desired…

1694

Abstract

Purpose

In the service sector, reduction of cycle time is one of the key issues. Among various approaches, Lean Six Sigma became very popular as it provides the organisation the desired speed with quality. The purpose of this paper is to present a Lean Six Sigma case study for reducing cycle time in the claim settlement process in insurance or financial services.

Design/methodology/approach

This paper presents an application of Lean Six Sigma methodology for claim settlement cycle time reduction in the insurance sector.

Findings

Lean Six Sigma is found to work very well in the insurance sector for reducing process cycle time by carrying out process changes. Mixing statistical and analytical techniques helps to improve the process speed and is very well demonstrated by Lean Six Sigma approach for service organizations.

Originality/value

This paper utilizes Lean and Six Sigma approaches in process improvement and presents an application. The main idea behind this paper is to demonstrate how combining Lean concepts/techniques with Six‐Sigma methodology can speed up problem‐solving approaches. Apart from the paper's value for managers, it can also help researchers to extend this for other areas of business processes.

Details

International Journal of Lean Six Sigma, vol. 4 no. 2
Type: Research Article
ISSN: 2040-4166

Keywords

Article
Publication date: 7 October 2014

Ashok Sarkar, Arup Ranjan Mukhopadhyay and Sadhan Kumar Ghosh

Practitioners often face challenges in model development when establishing a relationship between the input and output variables and their optimization and control. The purpose of…

1064

Abstract

Purpose

Practitioners often face challenges in model development when establishing a relationship between the input and output variables and their optimization and control. The purpose of this paper is to demonstrate, with the help of a real life case example, the procedure for model development between a key process output variable, called the multi-stage flash evaporator efficiency, and the associated input process variables and their optimization using appropriate statistical and analytical techniques.

Design/methodology/approach

This paper uses a case study approach showing how multiple regression methodology has been put into practice. The case study was executed in a leading Indian viscose fiber plant.

Findings

The desired settings of the relevant process parameters for achieving improved efficiency have been established by appropriately using the tools and techniques from the Lean Six Sigma tool kit. The process efficiency, as measured by M3 of water evaporated per ton of steam, has improved from 3.28 to 3.48 resulting in satisfactory performance.

Originality/value

This paper will be valuable to many practitioners of Six Sigma/Lean Six Sigma and researchers in terms of understanding the systematic application of quality and optimization tools in a real world situation.

Article
Publication date: 22 February 2013

Shri Ashok Sarkar, Arup Ranjan Mukhopadhyay and Sadhan Kumar Ghosh

In implementing Six Sigma and/or Lean Six Sigma, a practitioner often faces a dilemma of how to select the subset of root causes from a superset of all possible potential causes…

5259

Abstract

Purpose

In implementing Six Sigma and/or Lean Six Sigma, a practitioner often faces a dilemma of how to select the subset of root causes from a superset of all possible potential causes, popularly known as root cause analysis (RCA). Generally one resorts to the cause and effect diagram for this purpose. However, the practice adopted for identification of root causes is in many situations quite arbitrary and lacks a systematic, structured approach based on the rigorous data driven statistical analysis. This paper aims at developing a methodology for validation of potential causes to root causes to aid practitioners.

Design/methodology/approach

Discussion has been made on various methods for identification and validation of potential causes to root causes with the help of a few real life examples for effective Lean Six Sigma implementation.

Findings

The cause and effect diagram is the frequently adopted method for identifying potential causes out of a host of methods available for such identification. The method of validation depends on the practitioners’ knowledge on the relationship between cause and effect and controllability of the causes.

Originality/value

The roadmap thus evolved for the validation of root causes will be of great value to the practitioners as it is expected to help them understand the ground reality in an unambiguous manner resulting in a superior strategy for cause validation and corrective actions.

Details

The TQM Journal, vol. 25 no. 2
Type: Research Article
ISSN: 1754-2731

Keywords

Article
Publication date: 19 April 2013

E.V. Gijo and Ashok Sarkar

The purpose of this paper is to apply Six Sigma methodology, a systematic and structured approach for quality improvement in wind energy sector. This paper discusses the…

1368

Abstract

Purpose

The purpose of this paper is to apply Six Sigma methodology, a systematic and structured approach for quality improvement in wind energy sector. This paper discusses the development of sustainable wind farm roads for an organization engaged in manufacturing, installation and servicing of windmills in India.

Design/methodology/approach

This paper illustrates the Six Sigma DMAIC approach and its application for development of sustainable wind farm roads.

Findings

The systematic and data driven approach of Six Sigma methodology identified many root causes for road damages and solutions were implemented to ensure sustainable wind farm roads.

Originality/value

Six Sigma has been successfully implemented world over in different business processes ranging from manufacturing to service and health care. However its application is very uncommon in areas like road construction. This article demonstrates the applicability of Six Sigma methodology in uncommon areas.

Details

The TQM Journal, vol. 25 no. 3
Type: Research Article
ISSN: 1754-2731

Keywords

Article
Publication date: 10 October 2016

V. Raja Sreedharan and R. Raju

The purpose of this paper is to review Lean Six Sigma (LSS) literature and report different definitions, demographics, methodologies and industries.

4755

Abstract

Purpose

The purpose of this paper is to review Lean Six Sigma (LSS) literature and report different definitions, demographics, methodologies and industries.

Design/methodology/approach

This paper highlights various definitions by different researchers and practitioners. A total of 235 research papers has been reviewed for the LSS theme, research methodology adopted, type of industry, author profile, country of research and year of publication.

Findings

From the review, four significant LSS classifications were identified that deal with the spread of LSS in different industries followed by observation for classification.

Practical implications

LSS is a strategy for success, but it did not examine its presence in various Industries. From this paper, readers can understand the quantum of its spread before implementing LSS. For academicians, it will be a comprehensive list of papers for research.

Originality/value

This paper reviews 235 research papers for their year, author profile, research methodology and type of industry. Various characteristics of LSS definitions and their theme are also reviewed.

Details

International Journal of Lean Six Sigma, vol. 7 no. 4
Type: Research Article
ISSN: 2040-4166

Keywords

Article
Publication date: 11 March 2020

Meryem Uluskan and Ezgi Pınar Oda

The purpose of this study is to analyze door-panel alignment defects seen in built-in ovens manufactured in one household appliances company's plant. Alignment defects in oven…

1369

Abstract

Purpose

The purpose of this study is to analyze door-panel alignment defects seen in built-in ovens manufactured in one household appliances company's plant. Alignment defects in oven door panel substantially affect aesthetics of the product which is an important aspect in driving customer preference and satisfaction. Therefore, this study aimed to increase the initial 3.1 sigma level of oven-manufacturing process to at least 4 sigma level by decreasing a particular door-panel alignment defect, which constituted 67.7 percent of the overall alignment defects.

Design/methodology/approach

The goals were achieved through a structured Six Sigma implementation with lean element by utilizing various Six Sigma tools such as workflow, Pareto-analysis, measurement system analyses, control-charts, process capability analysis, cause-and effect-diagram and hypotheses tests. A non–value-added step was also eliminated through the lean approach.

Findings

Through Six Sigma implementation, the initial 3.1 sigma process performance level has been increased to 4.4 sigma level leading to substantial decrease in alignment defects.

Originality/value

In the quality management literature, not many papers directly deal with aesthetics and appearance problems of the products especially in the household appliances industry. Moreover, hypothesis testing is not frequently used in Six Sigma implementations in the literature. In addition to limited usage of hypothesis testing, very few studies conducted a thorough measurement system analysis. Considering these gaps in the Six Sigma literature, this study fills an important gap in research by implementing a detailed Six Sigma study, enhanced with hypothesis testing and a thorough measurement system analysis, on the aesthetics and appearance of the product.

Details

The TQM Journal, vol. 32 no. 6
Type: Research Article
ISSN: 1754-2731

Keywords

Article
Publication date: 30 August 2021

Omar Taha, Thomas A. Mazzuchi, Shahram Sarkani, Jiju Antony and Sandra Furterer

The purpose of this paper is to apply Lean in the workers’ compensation industry. It focuses on identifying patterns of repetitive non-value-added transnational activities for…

Abstract

Purpose

The purpose of this paper is to apply Lean in the workers’ compensation industry. It focuses on identifying patterns of repetitive non-value-added transnational activities for physical-therapy patients and healthcare providers. It addresses the research gap in this field.

Design/methodology/approach

In this study, we designed and deployed multiple case studies to better understand the journey of an injured worker within the worker compensation system in the United States of America. We partnered with Concentra Inc., a leading national healthcare provider in the field of workers’ compensation having 520 medical centers in 44 states. Both case studies included conducting direct observations, Gemba walk, in five clinics in two states: Florida and Pennsylvania. We analyzed the data of 263 injured workers with 8 or more physical therapy visits who got admitted to Concentra clinics in both states over the period of 31 days.

Findings

The results revealed that the time intervals at which activities associated with physical therapy treatment pre-authorization accounted for 91.59% of the total non-value-added activities and are thus the key administrative factor leading to process inefficiency in the state of Florida. The Process Cycle Efficiency of Pennsylvania was 75.36% compared to 53.16% of Florida. The injured workers in Florida needed 39.58 days on average to complete eight physical therapy visits compared to 27.92 days in Pennsylvania (a median of 34.09 vs 22.15 days).

Research limitations/implications

This study is limited as it only focuses on processes on the healthcare provider side. An expanded value stream map that includes the treatment pre-authorization process on the insurance side would be beneficial for generating more potential solutions to streamline the process.

Practical implications

This study shows that Lean could play a critical role in identifying and quantifying continuous improvement opportunities that could accelerate patient’s treatment, reduce administrative burden on healthcare providers and improve the overall claim cost of insurance companies. It provides data-driven argument for insurance companies to consider eliminating physical therapy pre-authorization.

Originality/value

This is the first study to apply Lean methodology in the workers’ compensation field.

Details

The TQM Journal, vol. 34 no. 5
Type: Research Article
ISSN: 1754-2731

Keywords

Article
Publication date: 6 July 2018

Shruti J. Raval, Ravi Kant and Ravi Shankar

The purpose of this paper is to examine and introduce comprehensive insights into the field of Lean Six Sigma (LSS) by reviewing the existing literature and identifying the…

1325

Abstract

Purpose

The purpose of this paper is to examine and introduce comprehensive insights into the field of Lean Six Sigma (LSS) by reviewing the existing literature and identifying the research gap. The state of LSS research is assessed by critically examining the field, along with a number of dimensions, including time horizon, year, journal and publisher, university, country, author, geographic analysis, research design, research affairs, research methods, tools/techniques used, focus industries, major research area, benefits gained by LSS, critical success factors and barriers of LSS implementation.

Design/methodology/approach

This paper is based on a systematic literature review of 190 articles containing the word LSS in their title, which are published in a well-known database, such as Elsevier ScienceDirect, Taylor and Francis, Emerald Full Text, Springer Link, Wiley InterScience and Inderscience from January 2000 to September 2016.

Findings

This analysis reveals 15 significant dimensions to identify the state of LSS research. Authors find a noticeable rise in the attention of LSS research in the available literature. Major findings show that, the empirical research holds greater credibility. Statistics prove that the case study method scores the highest among all the research methods used in the discipline. The largest number of studies have investigated research issues related to implementation and process of LSS. The LSS uses a wide range of tools/techniques/methodologies: the choice of tools is situation-specific. Manufacturing and health-care sectors have been the focus of LSS research, but LSS has also been adopted by other types of industries. The organizations following LSS have improved bottom-line results, improved company profitability and growth and enhanced customer satisfaction. In general the research is more interpretive in nature; there is still a lack of standard in the LSS implementation framework.

Research limitations/implications

This study is limited to reviewing those articles which contain the word LSS appeared in the title.

Originality/value

This study will help understand the current state of research on LSS, various trends in the field, its applicability and future prospects of investigation in the field.

Details

International Journal of Lean Six Sigma, vol. 9 no. 3
Type: Research Article
ISSN: 2040-4166

Keywords

1 – 10 of 46