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Open Access
Article
Publication date: 6 September 2022

Rose Clancy, Ken Bruton, Dominic T.J. O’Sullivan and Aidan J. Cloonan

Quality management practitioners have yet to cease the potential of digitalisation. Furthermore, there is a lack of tools such as frameworks guiding practitioners in the digital…

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Abstract

Purpose

Quality management practitioners have yet to cease the potential of digitalisation. Furthermore, there is a lack of tools such as frameworks guiding practitioners in the digital transformation of their organisations. The purpose of this study is to provide a framework to guide quality practitioners with the implementation of digitalisation in their existing practices.

Design/methodology/approach

A review of literature assessed how quality management and digitalisation have been integrated. Findings from the literature review highlighted the success of the integration of Lean manufacturing with digitalisation. A comprehensive list of Lean Six Sigma tools were then reviewed in terms of their effectiveness and relevance for the hybrid digitisation approach to process improvement (HyDAPI) framework.

Findings

The implementation of the proposed HyDAPI framework in an industrial case study led to increased efficiency, reduction of waste, standardised work, mistake proofing and the ability to root cause non-conformance products.

Research limitations/implications

The activities and tools in the HyDAPI framework are not inclusive of all techniques from Lean Six Sigma.

Practical implications

The HyDAPI framework is a flexible guide for quality practitioners to digitalise key information from manufacturing processes. The framework allows organisations to select the appropriate tools as needed. This is required because of the varying and complex nature of organisation processes and the challenge of adapting to the continually evolving Industry 4.0.

Originality/value

This research proposes the HyDAPI framework as a flexible and adaptable approach for quality management practitioners to implement digitalisation. This was developed because of the gap in research regarding the lack of procedures guiding organisations in their digital transition to Industry 4.0.

Details

International Journal of Lean Six Sigma, vol. 15 no. 5
Type: Research Article
ISSN: 2040-4166

Keywords

Open Access
Article
Publication date: 3 March 2023

Amy B.C. Tan, Desirée H. van Dun and Celeste P.M. Wilderom

With the growing need for employees to be innovative, public-sector organizations are investing in employee training. This study aims to examine the effects of a combined Lean Six…

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Abstract

Purpose

With the growing need for employees to be innovative, public-sector organizations are investing in employee training. This study aims to examine the effects of a combined Lean Six Sigma and innovation training, using action learning, on public-sector employees’ creative role identity and innovative work behavior.

Design/methodology/approach

The authors studied a public service agency in Singapore in which a five-day Lean Innovation Training was implemented, using a combination of Lean Six Sigma and Creative Problem-Solving tools, with a simulation on day one and subsequent team-based project coaching, spread over six months. The authors administered pre- and postintervention surveys among all the employees, and initiated group interviews and observations before, during and after the intervention.

Findings

Creative role identity and innovative work behavior had significantly improved six months after the intervention, enabled through senior management’s transformational leadership. The training induced managers to role-model innovative work behaviors while cocreating, with their employees, a renewal of their agency’s core processes. The three completed improvement projects contributed to an innovative work culture and reduced service turnaround time.

Originality/value

Starting with a role-playing simulation on the first day, during which leaders and followers swapped roles, the action-learning type training taught all the organizational members to use various Lean Six Sigma and Creative Problem-Solving tools. This nimble Lean Innovation Training, and subsequent team-based project coaching, exemplifies how advancing the staff’s creative role identity can have a positive impact.

Details

International Journal of Lean Six Sigma, vol. 15 no. 8
Type: Research Article
ISSN: 2040-4166

Keywords

Article
Publication date: 22 August 2024

Mohammad Al-Rifai

Optimizing manufacturing processes addresses operational challenges and yields significant benefits across the business spectrum. This study aims to comprehensively analyze a…

Abstract

Purpose

Optimizing manufacturing processes addresses operational challenges and yields significant benefits across the business spectrum. This study aims to comprehensively analyze a manufacturing process through value stream mapping (VSM), aiming to streamline operations, reduce production lead times and minimize work-in-process (WIP) inventory levels. These improvements directly enhance competitiveness, customer satisfaction and overall business success, enabling a swift response to market demands, timely delivery of high-quality products and cost-effectiveness.

Design/methodology/approach

The approach integrates current and future-state VSM concepts with Lean tools across four stages: problem definition, current-state VSM analysis, future-state VSM design and improvement implementation. A team assembled to improve the manufacturing process for electronic devices has successfully implemented this approach.

Findings

Implemented improvements significantly reduced WIP inventory (88.8% equivalent to $572,171 annually) and production lead time (from 28.26 to 3.21 days), enhancing operational flexibility and competitiveness. Streamlined processes led to a 13% decrease in cycle time and a notable reduction in daily rework (63.6%), amounting to $118,127 annually. Labor reduction (45.5%) yielded annual savings of approximately $594,000, with affected individuals successfully transitioning to other roles, highlighting the effectiveness of lean methodologies without job cuts.

Originality/value

This initiative exemplifies the effective use of VSM and Lean tools in optimizing an electronic device manufacturing operation that produces 43 products across various processes. By leveraging these methodologies, this research offers valuable insights into enhancing production efficiency, resulting in shorter production lead times, reduced cycle times and significant decreases in WIP inventory and rework.

Details

Measuring Business Excellence, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1368-3047

Keywords

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…

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

Keywords

Article
Publication date: 3 September 2024

Jaiveshkumar D. Gandhi and Shashank Thanki

India’s manufacturing sector employs about 12% of the labour force and contributes to about 17% of the nation’s GDP. The Indian government intends to implement several initiatives…

Abstract

Purpose

India’s manufacturing sector employs about 12% of the labour force and contributes to about 17% of the nation’s GDP. The Indian government intends to implement several initiatives under the “Make in India” and Atma Nirbhar Bharat banners to increase the manufacturing sector’s share of the nation’s GDP to 25% by 2025. Applying lean manufacturing, green manufacturing and Six Sigma is crucial to ensure that India’s manufacturing sectors grow sustainably in international markets. This study aims to identify sustainability indicators and ascertain their respective weights to evaluate the sustainability performance of the Indian manufacturing industry.

Design/methodology/approach

This research identifies 25 sustainability indicators and classifies them into the triple bottom line of sustainability based on an evaluative literature review and expert opinion. The Best Worst Method was utilised to determine the weights of the sustainability indicators. The sustainability index was developed to evaluate economic, social and environmental sustainability.

Findings

The sustainability performance of a foundry in a significant Western Indian State city was assessed by applying the developed sustainability index. After the adoption of integrated lean, green and Six Sigma (LG&SS) strategies and related practices in the foundry, there has been a notable improvement of 68.03% in the economic index, 61.62% in the social index and 13.24% in the environmental index.

Research limitations/implications

The proposed sustainability index is applied and evaluated specifically for assessing the sustainability performance of Indian manufacturing SMEs. It can be used to substantiate firm’s sustainability performance and also to assess the improvement in firm’s performance in economic, environmental and social dimensions after implementing various operational excellence practices. However, it cannot serve as a benchmark tool across similar companies or organisations.

Practical implications

The developed sustainable index can be used to analyse the company or organisation’s sustainability performance and see how various strategies have improved things. Practitioners can use this index to assess social, economic and environmental performance and focus on areas that need improvement.

Social implications

The proposed sustainability index serves as a vital tool for monitoring a firm’s progress in triple bottom line (TBL) dimensions of sustainability, tracking a diverse range of indicators and encouraging sustainable organisational practices.

Originality/value

This study attempts to assess the economic, social and environmental performance of Indian Manufacturing SMEs by proposing a sustainability index.

Details

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

Keywords

Open Access
Article
Publication date: 29 May 2024

Anna Trubetskaya, Olivia McDermott, Pierre Durand and Daryl John Powell

This project aims to optimise a secondary agricultural company’s reporting and data lifecycle by providing self-help business intelligence at an optimal price point for all…

Abstract

Purpose

This project aims to optimise a secondary agricultural company’s reporting and data lifecycle by providing self-help business intelligence at an optimal price point for all business users.

Design/methodology/approach

A design for Lean Six Sigma approach utilising the define, measure analyse, design and verify methodology was utilised to design a new reporting and data product lifecycle.

Findings

The study found that this approach allowed a very structured delivery of a complex program. The various tools used assisted greatly in delivering results while balancing the needs of the team.

Practical implications

This study demonstrates how improving data analysis and enhanced intelligence reporting in agribusinesses enable better decision making and thus improves efficiencies so that the agribusiness can leverage the learnings.

Social implications

Improving data analysis increases efficiency and reduces agrifood food wastage thus improving sustainability and environmental impacts.

Originality/value

This paper proposes creating a standardised approach to deploying Six Sigma methodology to correct both the data provisioning lifecycle and the subsequent business intelligence reporting lifecycle. It is the first study to look at process optimisation across the agricultural industry’s entire data and business intelligence lifecycle.

Details

The TQM Journal, vol. 36 no. 9
Type: Research Article
ISSN: 1754-2731

Keywords

Article
Publication date: 20 September 2024

César Cuevas, Ignacio Mira-Solves and Antonio Verdu-Jover

In the evolving landscape of Industry 5.0 (I5.0), which emphasises sustainability, human-centricity and resilience, mapping the current interrelationship and future research…

Abstract

Purpose

In the evolving landscape of Industry 5.0 (I5.0), which emphasises sustainability, human-centricity and resilience, mapping the current interrelationship and future research directions, the role of Lean Six Sigma (LSS) methodology remains underexplored. Our study addresses this gap by examining the potential of LSS to support I5.0 while identifying areas for further investigation.

Design/methodology/approach

This study's multifaceted approach, which includes systematic literature review (SLR), bibliographic network analysis (BNA) and expert validation (EV), provides a holistic exploration of the interaction between LSS and I5.0 as the basis for well-founded conclusions.

Findings

The analysis yields several valuable insights. Firstly, it demonstrates the absence of a direct link between LSS and I5.0. Secondly, the substantial body of literature analysed establishes connections between LSS and its pillars. Thirdly, the analysis identifies points of intersection, difference and similarity between LSS and I5.0, highlighting the potential of LSS to facilitate implementation of I5.0 through its proven methodologies, continuous improvement culture, risk management, error learning, human–machine collaboration and training and skill development.

Originality/value

This study pioneers the effort to realise the latent potential of LSS in the context of I5.0. Its systematic identification of the synergies between these paradigms fills a critical gap in the literature and gives policymakers, managers and researchers a guide for informed decision-making to maximise the benefits of I5.0 for individuals, companies, society and the planet.

Details

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

Keywords

Open Access
Article
Publication date: 22 February 2024

Katsutoshi Fushimi

Prior institutional duality research asserts that ceremonial implementation of organisational practice protects multinational corporations’ subsidiaries. However, the temporal…

Abstract

Purpose

Prior institutional duality research asserts that ceremonial implementation of organisational practice protects multinational corporations’ subsidiaries. However, the temporal dynamics of the safeguarding function has been under researched. Public sector organisations have also been ignored. This research aims to explore how the safeguarding function is created, maintained and disrupted using the overseas offices (OOs) of a bilateral development agency (BDA) as a case.

Design/methodology/approach

A multi-case study, underpinned by neo-institutionalism, was conducted. Data obtained from in-depth remote interviews with 39 informants from the BDA OOs were analysed using the “asking small and large questions” technique, four analytical techniques, cross-case synthesis and theoretical propositions.

Findings

A three-phase process was identified. The first phase is the appearance of discrepancies due to institutional duality. The second is the emergence of ceremonial implementation as a solution. In the third phase, “the creation, maintenance and disruption of a safeguarding function” begins. When ceremonial implementation successfully protects the OOs, the safeguarding function is created. The OOs are likely to repeat ceremonial implementation, thus sustaining the function. Meanwhile, when conditions such as management staff change, ceremonial implementation may not take place, and the safeguarding function disappears.

Research limitations/implications

The BDA OOs may not face strong host country regulative pressures because they are donors to aid-recipient countries. Hence, the findings may not directly apply to other public sector organisations.

Practical implications

Development cooperation practitioners should understand that ceremonial implementation is not exclusively harmful.

Originality/value

To the best of the author’s knowledge, this is the first institutional duality research that explores the temporal dynamics of safeguarding functions targeting public sector organisations.

Details

International Journal of Organizational Analysis, vol. 32 no. 11
Type: Research Article
ISSN: 1934-8835

Keywords

Open Access
Article
Publication date: 18 June 2024

Kristin Samantha Williams

The aim of this study is two-fold: (1) to promote a model of youth participatory research and offer a window of understanding into how it can be enacted and (2) to understand…

Abstract

Purpose

The aim of this study is two-fold: (1) to promote a model of youth participatory research and offer a window of understanding into how it can be enacted and (2) to understand youth perspectives on youth empowerment. This study asks: “how can youth help us understand youth empowerment?”

Design/methodology/approach

The study applies youth participatory action research (YPAR) and interpretative phenomenological analysis. The study illustrates how to enact a model of YPAR by engaging youth in the process of research in a youth-serving community non-profit organization.

Findings

This study sets out to make two important contributions, one methodological and one theoretical: First, the study contributes to our understanding of the opportunities and benefits of youth-engaged, peer-to-peer research. Specifically, this study promotes a model of youth participatory action research and knowledge making processes, and the associated social and formal benefits for youth. By extension, this study illustrates an approach to engage youth in formal contexts which has implications for both management and organizational studies and education. Finally, the study extends our understanding and conceptualization of the phenomenon of youth empowerment (as informed by youth perspectives).

Originality/value

The study offers insight into how to conduct youth participatory action research and specifically how to address two limitations cited in the literature: (1) how to authentically engage youth including how to share power, and (2) how to perform youth participatory action research, often critiqued as a black box methodology.

Details

Qualitative Research in Organizations and Management: An International Journal, vol. 19 no. 5
Type: Research Article
ISSN: 1746-5648

Keywords

Open Access
Article
Publication date: 4 July 2024

Bart Lameijer, Elizabeth S.L. de Vries, Jiju Antony, Jose Arturo Garza-Reyes and Michael Sony

Many organizations currently transition towards digitalized process design, execution, control, assurance and improvement, and the purpose of this research is to empirically…

Abstract

Purpose

Many organizations currently transition towards digitalized process design, execution, control, assurance and improvement, and the purpose of this research is to empirically demonstrate how data-based operational excellence techniques are useful in digitalized environments by means of the optimization of a robotic process automation deployment.

Design/methodology/approach

An interpretive mixed-method case study approach comprising both secondary Lean Six Sigma (LSS) project data together with participant-as-observer archival observations is applied. A case report, comprising per DMAIC phase (1) the objectives, (2) the main deliverables, (3) the results and (4) the key actions leading to achieving the presented results is presented.

Findings

Key findings comprise (1) the importance of understanding how to acquire and prepare large system generated data and (2) the need for better large system-generated database validation mechanisms. Finally (3) the importance of process contextual understanding of the LSS project lead is emphasized, together with (4) the need for LSS foundational curriculum developments in order to be effective in digitalized environments.

Originality/value

This study provides a rich prescriptive demonstration of LSS methodology implementation for RPA deployment improvement, and is one of the few empirical demonstrations of LSS based problem solving methodology in industry 4.0 contexts.

Details

Business Process Management Journal, vol. 30 no. 8
Type: Research Article
ISSN: 1463-7154

Keywords

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