Critical success factors of TQM, Six Sigma, Lean and Lean Six Sigma

A balanced approach involving hard and soft factors for internalizing Lean Management and Six Sigma in hospitals

Purpose

This study examines the theoretical and empirical relationships between LM&SS, human resource management (HRM), climate for LM&SS and outcomes (employee well-being and performance) in hospitals. As part of this research, the authors examine the interplay between “hard” and “soft” practices for LM&SS and “soft” HR practices.

Design/methodology/approach

A cross-sectional, multisite survey study covering all internal service units at all eight Dutch university hospitals was conducted (42 units, N = 218 supervisors, N = 1,668 employees), and multivariate multilevel regression analyses were performed.

Findings

A systems approach involving “soft” LM&SS practices that are specifically HR-related has a positive effect (β is 0.46) on a climate for LM&SS. A climate for LM&SS is not related to perceived performance or employee health. It is, however, positively related to employee happiness and trusting relationships (both βs are 0.33). We did not find that a climate for LM&SS had a mediating effect.

Research limitations/implications

This study shows that a balanced approach involving both “hard” and “soft” factors is crucial to achieving the desired breadth and depth of LM&SS adoption at the macro, meso, and micro levels. The authors found that a climate for LM&SS positively affects employee well-being in hospitals.

Practical implications

In their attempt to create mutual gains for both their organization and their employees, hospitals that adopt LM&SS should foster a climate for LM&SS by embracing a balanced approach consisting of both “hard” and “soft” practices, thereby internalizing LM&SS at the macro, meso, and micro levels.

Originality/value

This is one of the first studies to examine in-depth the impact of “hard” and “soft” LM&SS on both employee well-being (subdivided into different components) and performance in healthcare, as well as the role of “soft” HRM in this relationship. Linking LM&SS, HRM and outcomes to a climate for LM&SS is relatively a new approach and has led to a deeper understanding of the mechanisms underpinning the internalization of LM&SS in healthcare.

Application of six sigma and the system thinking approach in COVID-19 operation management: a case study of the victorian aged care response centre (VACRC) in Australia

COVID-19 has posed many unique and critical challenges in various contexts and circumstances. This often led the stakeholders and decision-makers to depart from traditional thinking and the business-as-usual processes and to come up with innovative approaches to tackle various mission-critical situations within a short time frame. In this paper, a real-life case study of COVID-19 operation management following a multi-disciplinary, multi-stakeholder novel integrated approach in aged care facilities in Victoria, Australia, is presented which yielded significant and positive outcomes. The purpose of the intervention was to develop an integrated system performance approach through the application of various quality management tools and techniques to achieve organizational excellence at the aged care centers. The case involved the use of mathematical models along with statistical tools and techniques to address the specific problem scenario. A system-wide management plan was proposed, involving various agencies across several residential aged care facilities during the pandemic. A three-step methodological framework was developed, where Six Sigma, a system thinking approach, and a holistic metric were proposed to manage the value chain of the pandemic management system. The experimental result analyses showed significant improvement in the management process, suggesting the validity and potential of this holistic approach to stabilize the situation and subsequently set the conditions for operations excellence within the sectors. The model offers new insight into the existing body of knowledge and offers an efficient approach to achieving operational excellence in any organization or business regardless of its type, shape and complexity, which can help practitioners in managing complex, mission-critical situations like a pandemic.

An empirical study into the reasons for failure of sustaining operational excellence initiatives in organizations

Purpose

Operational excellence (OPEX) initiatives such as Lean, Six Sigma, Lean Six Sigma and Agile have some common characteristics that can be understood through their adoption in organizations. The objective of this research is to present the results of an online survey highlighting the most critical reasons for failure of OPEX initiatives.

Design/methodology/approach

This study presents the results of a survey from 106 experts from different countries who have been involved in OPEX implementation. The experts were Six Sigma Master Black Belts, Black Belts and Champions from different manufacturing and service organizations. The developed questionnaire was initially tested with the help of seven experts to ensure their technical validity and soundness.

Findings

The study found 15% of companies surveyed have not adopted any form of OPEX methodology. The top three reasons for non-adoption of OPEX were also found. In terms of the use of various OPEX methodologies, more than 75% of companies were employing Six Sigma and less than 50% were engaged in Lean initiatives. Another surprising result was that less than 5% of the companies were utilizing Kaizen and other continuous improvement methodologies for improving the efficiency and effectiveness of organizational processes. The study further finds top five failure factors for sustaining OPEX initiatives in manufacturing, service, large and small organizations.

Research limitations/implications

The study reports the outcomes based on an online survey with limited sample size. Moreover, the number of samples from small and medium-sized enterprises (SMEs) was less than 25, and therefore it was difficult to make any robust conclusions in the comparison of failure factors between large enterprises and SMEs.

Originality/value

To the best of the authors’ knowledge, this is the first empirical study that has attempted to explore the reasons for failure of OPEX initiatives. The authors argue that a greater understanding of the reasons for failure of OPEX initiatives can provide an input to develop a framework that can mitigate the failures and costs associated with such failures.

Quality 4.0 – understanding the criticality of the dimensions using the analytic hierarchy process (AHP) technique

Purpose

In this era of Industry 4.0, characterized by disruptive technologies, there is a need to identify and understand the role of the quality function in the excellence journey. Quality 4.0 refers to the digitalization of quality work in the context of Industry 4.0. As Quality 4.0 is a new concept, empirical research on the subject is extremely scant. Therefore, this study aims to identify and understand the criticality of the dimensions of Quality 4.0.

Design/methodology/approach

The present research identifies 12 axes (dimensions) of Quality 4.0 based on literature review and inputs from experts. The identified axes have been prioritized using the analytic hierarchy process (AHP) technique.

Findings

The study concludes that the 12 dimensions contribute to outcome indicators such as organizational performance, agility and sustainability. It further adds that though technology is vital for Quality 4.0, elements of traditional quality such as leadership, quality culture, customer focus, quality systems, compliance, competence, analytical thinking, data-driven decision making, etc. are mandatory for the transformation journey. In today's context except for a few matured organizations, others are even struggling to implement the traditional aspects of quality.

Research limitations/implications

Cues to further research are provided which would help in the better understanding of Quality 4.0 and its role in the Industry 4.0 scenario.

Practical implications

This research would help the practitioners understand the determinants of Quality 4.0 system and their effects on organizational performance, agility and sustainability.

Originality/value

The present research work strives to throw light on the criticality of the dimensions of Quality 4.0, thereby contributing to theory building, especially given the paucity of literature in Quality 4.0.

Seizing the opportunity: the emergence of shared leadership during the deployment of an integrated performance management system

Background

Performance management systems have been introduced in health and social services institutions to improve organizational performance, supporting the emergence of new management behaviors that are more rooted in collaborative management practices. This study aims to understand how different leadership styles emerge through the implementation of a performance management system and its related tools, and how these can foster distributed leadership.

Methods

Over two years, the implementation of an integrated performance management system supporting the integration of social services for children, youth, and families was studied at a recently merged Canadian healthcare organization. Qualitative analysis of data collected from 15 interviews, 3 focus groups, and over 350 h of non-participant observation was conducted.

Results

The results show that leadership evolved to adapt to the context of organizational integration and was no longer confined to a single manager. Transformational leadership was needed to encourage the emergence of a new integrated performance management system and new behaviors among middle managers and team members. Transactional leadership was legitimized through the use of a status sheet when the integration project did not deliver the expected results. Both transformational and transactional leadership paved the way to distributed leadership, which in turn promoted collaborative practices associated with activities in control rooms and dialogue stemming from the status sheets. Distributed leadership among team members made a difference in the outcome of the integration project, which became a driver of collaboration.

Conclusions

The integrated performance management system and the use of its tools can help renew leadership in health and social service organizations. The results lend credence to the importance of distributed leadership in promoting collaborative practices to improve services for children, youth, and families. The results also highlight how various leadership styles can contribute to the emergence of distributed leadership over time.

The implementation of Lean Six Sigma framework in the Indian context: a review and suggestions for future research

Purpose

The purpose of this work is to gain insights about Lean Six Sigma (LSS) in the Indian context by reviewing the related literature for one decade based on various perspectives, such as author profile, year of publication, type of firm, type of methodology used, type of industry for which the research work is carried out and the key findings from the research.

Design/methodology/approach

This study reviews the research related to LSS from the articles published in the reputed journals. The literature used for reviewing is derived from the sources, including Science direct, Google scholar, IEEE, Taylor and Francis Group, Emerald Insight, Springer, Inderscience and Elsevier during the period between 2010 and 2021. Totally, the authors have included 141 LSS-related research articles that are published in the Indian context. The keywords used are Lean Six Sigma, Lean Six Sigma in the Indian context, Lean Sigma and LSS to identify and consolidate the research papers published during this timeframe.

Findings

The research papers collected from various reputed journals, including Scopus and non- Scopus enlisted, are classified and grouped under various categories to identify the class of author who publishes more in this field, research trend over the years, the type of firm which implements LSS, the research methodology which is commonly used in LSS and related research and also the key takeaway from these articles are highlighted. Further, the authors have also identified the major contributions of researchers in various sectors during this period in India.

Originality/value

This classification framework and the systematic review help in identifying the research gap and in giving directions for future researchers. It will be useful for researchers and practitioners working on the area of LSS, rural and urban entrepreneurs, start-up managers, professionals working in micro, small and medium enterprises (MSMEs) and executives of the Make in India Project to make India as Aatmanirbhar Bharat Abhiyan. Further, the clear direction of progress over the current decade in manufacturing industries, service sectors and processing industries can help the professionals working in these sectors.

Strategies for successful deployment and sustainment of Lean Six Sigma in healthcare sector in India: a multi-level perspective

Purpose

This study aims to present Lean Six Sigma (LSS) deployment and sustainment strategies for the healthcare sector from a multi-level perspective. The objective is to present LSS implementation insights to enable policymakers, practitioners and academicians to test and develop an LSS framework for healthcare sectors.

Design/methodology/approach

The strategies identified are the result of a multi-method research design involving literature review, action research (AR) and Delphi study. Further, the AR portion of the study involved more than 10 years of projects focused on the deployment of LSS in the healthcare sector.

Findings

The strategies include a holistic view from the multi-level perspective, considering the Top Management Level, Middle Management Level and Operational Level. The authors ascertained 27 strategies across the three levels of organizational structure for the effective deployment of LSS. Further, the authors present a customized LSS “pocket guide” from the healthcare perspective for quick reference.

Research limitations/implications

The strategies delineated in this study are based on the Indian healthcare section only; thus, further research in additional geographic contexts is needed. Also, further research is necessary to provide additional empirical validation of the effects of the identified strategies on LSS program outcomes and to verify that the strategies operate at the proposed organizational levels. Future research should also focus on identifying the interrelationships between strategies within and across levels, developing a “road map” for LSS implementation in hospitals and designing the LSS curriculum for medical schools and other medical training programs.

Practical implications

Observations of this study can contribute to developing a holistic framework for successful LSS implementation in the healthcare sector for academicians, practitioners and policymakers. This, in turn, ensures an enhanced value proposition, improved quality of life and reduced healthcare operational costs. Thus, it ensures a win-win situation among all the stakeholders of the healthcare sector.

Originality/value

The strategies put forth will enable the LSS researchers, academicians and, more particularly, practitioners to delve deeper into specific enablers and safeguard the LSS deployment from backlash. The research has two significant benefits. Firstly, it enhances the understanding of LSS from the healthcare perspective. Secondly, it provides direction for future studies with specific components for hospitals’ LSS framework, which can be further tested, refined and improved.

Barriers and Enablers for Continuous Improvement Methodologies within the Irish Pharmaceutical Industry

This study aims to investigate the barriers that exist when implementing continuous improvement methodologies, such as Lean Six Sigma (LSS), within the Irish Pharma industry. The main finding of this study is that 45% of participants perceived that a highly regulated environment could be a barrier to continuous improvement implementation, while 97% of respondents utilised Continuous improvement (CI) methods, such as Lean, Six Sigma, and LSS, within their organisations. While the International Conference of Harmonisation integrates CI into its Pharmaceutical Quality Systems (PQS) regulations, the highest motivation for CI implementation amongst the Irish Pharma industry is to improve Productivity and Quality. The main obstacles highlighted for CI implementation in Pharma attributed to stringent regulatory regimes were fear of extra validation activity, a compliance versus quality culture, and a regulatory culture of being “safe”. Another relevant finding presented in this paper is that participants CI LSS tools are very strongly integrated into the pharma industries corrective and preventative action system, deviations, and internal audit systems. Limitations of the research are that all the data collected in the survey came from professionals working for multinational Pharmaceutical companies based in Ireland. The authors understand that this is the first research focused on the barriers and status of CI initiatives in the pharmaceutical industry. The results of this study represent an important step towards understanding the enablers and obstacles for the use of continuous improvement methodologies in pharmaceutical manufacturing industries on a global scale.

Quality management practices and quality of work life – a conceptual model development

Purpose

The present study analyzes the research articles linking quality management practices (QMP) and quality of work life (QWL). The investigation leads toward the formulation of the hypothesis and developing a conceptual framework of QMP and QWL.

Design/methodology/approach

The study uses a systematic literature review to explore the relationship between QMP and QWL using the Scopus, Web of Science, PubMed, Eric, IEEE Xplore, ScienceDirect, Directory of Open Access Journals (DOAJ), and Google Scholar database and identifies critical factors of QMP and QWL using Pareto analysis. Further study proposes a conceptual framework of articles linking QMP and QWL.

Findings

A thorough review of the literature identifies three different categories of research articles: “factor identification” articles, “QMP implementation” articles, “scale development” articles, and “influence of QMP on various organizational and employees-related factors” articles. Many studies have attempted to study the relationship and influence of QMP on employee-related factors but not by considering them holistically, thus, underlining the significant gap in the QMP and HRM literature.

Research limitations/implications

To review the literature on QMP and QWL, only a handful of databases were reviewed. Further, the proposed conceptual model is based on the QMP and QWL/HRM literature review, and it is not empirically validated. Further research can be considered to test and validate the proposed conceptual framework empirically.

Practical implications

This study highlights a gap in the existing research studies and an incomplete consideration of employees' aspects of QWL. Researchers and organizations are advised to adopt a broader view while assessing QMP implementation's influence on employees.

Originality/value

This study uses a systematic literature review and Pareto analysis to find the critical factors of QMP and QWL, thus providing a new research avenue for researchers, quality experts and human resource managers to consider all the aspects of employees, that is, QWL of employees, to understand the influence of QMP on employees to achieve firm success.

Assessment of quality performance in the Egyptian manufacturing industry

Purpose

The purpose of this study was to examine the quality performance of the Egyptian manufacturing industry based on Flynn's quality management practices framework.

Design/methodology/approach

A literature-based questionnaire was developed to collect the research data. The sample studied included 193 professionals from different manufacturing firms in Egypt. The research model utilized seven first-order constructs to measure infrastructure and core quality practices and the model was analyzed by structural equation modeling.

Findings

The results of the study showed that infrastructure practices had a positive effect on core quality practices, which in turn, significantly influenced quality performance. The findings confirmed that Egyptian manufacturing firms have a good foundation of quality management practices enabling them to improve quality performance.

Practical implications

This study provides a foundation for Egyptian manufacturing firms to develop a practical plan for implementing total quality management (TQM). In addition, the results of this study will help managers and policy makers develop a thorough understanding of the current status of TQM initiatives, enablers and barriers in Egypt.

Originality/value

The study represents one of the few attempts to examine quality practices and quality performance in the manufacturing sector in Egypt. To the best of the author's knowledge, this is the first study to examine these parameters in this context in Egypt.

Addressing strategic human resource management practices for TQM: the case of an Indian tire manufacturing company

Purpose

This study aims to identify SHRM (strategic human resource management) essential practices for the TQM (total quality management) program regarding an Indian tire manufacturing company and formulate an inclusive interrelationship to prioritize them.

Design/methodology/approach

Semistructured interview with ten experts from the company was made to give SHRM practices scores. The SLR (systematic literature review) and TOPSIS (technique for order of preference by similarity to ideal solution) techniques are used to establish the model for 12 key practices and rank them afterward.

Findings

The findings clearly show that strategic planning and staffing, teamwork and leadership development have appeared as the top three essential practices. Simultaneously, performance measurement and evaluation, work design and analysis and promotion are identified as the bottom three practices. These essential practices are identified as contributing attributes.

Practical implications

The findings prioritize the SHRM practices as contributing attributes that help other tire manufacturing industries identify their key practices. Moreover, it provides the necessary inputs comprised of ten experts' decisions to become more active and well prepared.

Originality/value

The novelty of this study is to identify the key practices by using SLR and measured by the TOPSIS method to rank and consider a tire manufacturing company as a case-based approach to gain high productivity and competitive advantage.

Effect of Quality Lean Manufacturing Tools on Commercial Benefits Gained by Mexican Maquiladoras

Companies implement lean manufacturing (LM) tools in their production processes to reduce waste; however, it is difficult to quantify the effect on benefits gained after their implementation. This article proposes a structural equations model (SEM) that relates three LM tools associated with quality as total quality management (TQM), waste, and right first time (RFT) as independent variables associated with commercial benefits gained as a dependent variable. Those four variables were related by six hypotheses that were validated with information from 169 responses to a survey applied to the Mexican maquiladora industry. Partial least squared was used to validate the hypotheses as direct effects. The sum of indirect and total effects was also estimated, and a sensitivity analysis was developed for relationships between variables. Findings indicate that TQM directly affects waste reduction, drives doing RFT, and directly and indirectly affects the commercial benefits gained.

Critical success factors for lean six sigma in quality 4.0

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.

The effect of total quality management-enabling factors on corporate social responsibility and business performance: evidence from Vietnamese coffee firms

Purpose

This article aims to evaluate total quality management (TQM)-enabling factors' impact on corporate social responsibility (CSR) activities and business performance through evidence from Vietnamese coffee firms.

Design/methodology/approach

Based on collecting data via in-depth face-to-face interviews with employees, who are working in the Vietnamese coffee companies. The partial least squares structural equation modeling (PLS-SEM) approach has been employed to investigate the relationship among the TQM-enabling factors, corporate social performance (CSP) and business performance.

Findings

A total of 13 TQM-enabling factors have been identified and divided into two categories, namely human and functional. The statistical results revealed a positive signal to remarkably enhance CSP and business performance by adopting those TQM-enabling factors into Vietnamese coffee firms.

Research limitations/implications

The framework model of this research should be evaluated in different contexts worldwide or in another sector that can further identify the TQM-enabling factor and the correlation among these constructs.

Practical implications

This article provides top managers of Vietnamese coffee firms with knowledge of TQM-enabling factors that may enable them to meet superior performance, including CSP, finance and reputation.

Originality/value

This is a unique study to employ the approach into the Vietnamese coffee industry context up-to-date, which is one of the essential sectors affecting Vietnam's sustainable development.

Critical factors for total quality management implementation in the Brazilian construction industry

Purpose

This paper aims to identify the critical success factors (CSFs) that affect the implementation of total quality management (TQM) and to investigate, from the perspective of Brazil, the latent factors for TQM implementation in the construction industry.

Design/methodology/approach

The methodology consists of two methods. First, a literature review was conducted to identify CSFs for TQM implementation. Then, empirical research was conducted from a survey questionnaire applied to 130 professionals who have experience in the Brazilian construction industry. SPSS version-25 was used for data analysis, using descriptive statistics, and, finally, principal component analysis for identifying the latent factors.

Findings

The study findings portray convergences regarding the practitioners' perception in the light of the 20 critical factors identified in the literature, which can serve to make construction professionals aware of the key factors to TQM implementation. In addition, two latent factors, quality practices and human factor were identified, and they can assist the leaders and decision-makers for the implementation of TQM in the construction industry of a developing country.

Originality/value

It fills the gap of practical studies that compare the academic and practitioners' perspectives regarding the CSFs for TQM implementation in construction industry.

Exploring the Drivers and the Interventions towards Sustainable Food Security in the Food Supply Chain

The sustainability of food security is a global concern, and one of the priorities related to it is the ability to identify effective efforts that can protect food security along the food supply chain (FSC). The present study demystifies the relation of sustainability and food security and structurally identifies the sustainable drivers, and the pragmatic interventions that can critically contribute to the sustainability of food security within each stage of the FSC. A systematic review of articles from six databases was implemented. Thematic analysis was engaged to detect the sustainable drivers and interventions practised at each stage in the FSC for food security purposes. Six main themes of the drivers and interventions were derived from the analysis: food security governance involvement, input resource management, output management, information sharing, income, and technology. The result identifies the potential that quality management has on the mediating effect towards sustainable food security, through which a conceptual model for sustainable food security in the FSC was thus developed. It is deduced that mapping and categorizing the drivers and intervention of sustainable food securities could help deepen the understanding of effective and innovative practices towards food security in the FSC.

Twenty-five years’ contribution of “Benchmarking: an International Journal” to manufacturing strategy: a scientometric review

Purpose

This study aims at reviewing the articles on the themes of manufacturing strategy (MS) published in “Benchmarking: An International Journal (BIJ)” and investigating the trends of publication for future research.

Design/methodology/approach

Five-stage methodology to conduct a literature review is adopted comprising: (1) article collection, (2) inclusion/exclusion criteria, (3) reviewing the articles, (4) analyzing the articles and (5) future research directions. A total of 57 articles specific to MS domain published in BIJ are reviewed. Further, a bibliometric analysis comprising keywords co-occurrence, citation and co-citation using a VOSviewer© software followed by content analysis to analyze the type of research, type of industry and type of tool/method used is carried out.

Findings

The study helps to find the scope of the journal and research gaps in the MS domain to provide future research directions. Most of the work found is survey-based or case-based in nature. However, there is a need for empirical research to be done in the field of MS.

Research limitations/implications

The study facilitates researchers willing to publish in BIJ to understand different themes of accepted papers concerning MS domain. The identified research gaps and future research direction can motivate researchers and practitioners to coin new approaches in the MS domain.

Originality/value

A comprehensive review and analysis of the MS literature published in BIJ has been provided. To the best of authors' knowledge, the current study is the only review study in MS domain focusing on one specific journal.

Analyzing barriers and strategies for implementing Lean Six Sigma in the context of Indian SMEs

Purpose

The purpose of this study is to investigate the barriers for implementing Lean Six Sigma (LSS) in small and medium-sized enterprises (SMEs) and present a framework that provides prioritized strategies to overcome the barriers.

Design/methodology/approach

The barriers and strategies are identified via a comprehensive literature review and validated by industry experts. The study uses the fuzzy Technique for Order of Preference by Similarity to Ideal Solution (fuzzy TOPSIS) to analyze the barriers and strategies for determining the prioritized list of strategies.

Findings

The findings reveal that there are sixteen barriers to LSS implementation in Indian SMEs. To overcome these barriers, this study reveals twelve strategies. The analysis shows that “effective management” is the most crucial strategy to overcome the barriers for implementing LSS in Indian SMEs.

Research limitations/implications

This research guides SMEs practitioners to efficiently and effectively implement LSS, which, in turn, can enhance the performance of SMEs.

Originality/value

This study contributes to the literature by integrating the strategies with the barriers for implementing LSS in Indian SMEs. Besides, this study provides the prioritized list of strategies to overcome the barriers for implementing LSS in Indian SMEs.

Analyzing the Lean Six Sigma enabled organizational performance to enhance operational efficiency

Purpose

The aim of this analysis is to review the Indian manufacturing organizations practicing Lean Six Sigma (LSS) tools/techniques with an objective of monitoring the performance of an organization and to develop recommendation for strategies to benchmark organizational operational efficiency.

Design/methodology/approach

This study offers insights of the LSS performance measurement aspects of the Indian manufacturing organizations based on Data envelopment analysis (DEA) approach. The five inputs and two outputs are considered on the basis of literature review and discussed with the practitioners.

Findings

In this analysis, the relative efficiency score of 18 Indian manufacturing organizations has been determined in order to assist evaluation of the impact of monetary investment on the outputs. The present analysis not only investigates the optimum level of input variables but also lays down a significant observation that an organization having higher profit and inventory turnover ratio is not necessarily an efficient organization.

Practical implications

The results assist to determine the best practice units, potential source of inefficiency and deliver beneficial data for the consistent enhancement of the operational efficiency. The DEA results assist managers and decision makers to derive appropriate strategies to enhance their performance with reference to the efficient organization and to regard it as their role model.

Originality/value

This analysis renders a DEA based framework of LSS practicing Indian manufacturing organizations. The framework is unique in terms of its input-outputs variable selection and measurement procedure.

How do organizations implement an effective LSS initiative? A qualitative study

Purpose

Lean Six Sigma (LSS) is one of the most popular and widely used business improvement methodologies. However, many organizations discontinue LSS despite a plethora of studies on the critical success factors. The purpose of this study is to answer the research question how do organizations implement an effective LSS initiative?

Design/methodology/approach

Qualitative study is conducted on managers working in companies using LSS for a long time. The data were analysed using Colaizzi method.

Findings

Twelve factors were identified which were responsible for the effective implementation of LSS. They are financial performance, organization-wide LSS culture, organization-wide innovation culture, continuous training and retraining of employees on LSS, continuous top management support, linking LSS to business strategy, linking LSS to the customer, project selection strategy, communication, recognition and compensation systems, social benefits and green benefits.

Originality/value

This is the first study to investigate the effective implementation of LSS initiative in the organization.

Lean meeting buyer's expectations, enhanced supplier productivity and compliance capabilities in garment industry

Purpose

Investigate the potential of using “lean” in garment supplier factories to enhance productivity and compliance capability, so as to fulfill a buyer's expectation of lower price, shorter lead time, and higher occupational health and safety (OHS) standards.

Design/methodology/approach

By means of an intervention, lean tools integrated with OHS elements were introduced in four Bangladeshi key garment suppliers of a Danish buyer. By employing a qualitative approach, both quantitative and qualitative techniques were used to collect data on productivity, OHS, and buyer–supplier efforts.

Findings

This study demonstrates that lean tools, integrated with OHS elements, can be used to improve the productivity and compliance capabilities of supplier firms, which meet a buyers' changing demands for lower prices, shorter lead times, and higher compliance standards. This study suggests that the improvement of productivity and OHS in supplier firms through lean implementation could be a better choice for buyers than switching to new suppliers with uncertainties in productivity and delivery, as well as OHS compliance problems.

Practical implications

The findings of this study suggest that garment suppliers can benefit from implementing lean, thereby improving their capacity to meet buyers' expectations. Therefore, both suppliers and buyers have a mutual interest in the application of lean in suppliers' production facilities.

Originality/value

By considering both buyer and supplier perspectives, this research is a unique attempt to investigate the possibilities of lean implementation at the shop-floor level to meet the market challenges in the context of a developing country.

Lean Six Sigma in manufacturing process: a bibliometric study and research agenda

Purpose

The purpose of this paper is to develop a bibliometric study about Lean Six Sigma (LSS) in the manufacturing process and to conduct an analysis of sources of publication, authorship, citations and other bibliometric indicators. This paper also identifies the research agenda for future research related to the LSS approach in manufacturing processes.

Design/methodology/approach

A total of 508 articles published during the period 2002 to 2017 were collected through an automated process from the Scopus and Web of Science databases and later analyzed using techniques such as data mining, bibliometric indicators analysis, cluster analysis, network analysis and word cloud. The boundaries of the study cover studies directed to the manufacturing processes.

Findings

The research identified 1,110 authors from 54 countries and 15 most prolific journals among the 162 journals investigated. The study unveils relevant articles, authors and journals that have discussed LSS initiatives in the manufacturing process.

Practical implications

The study findings can make practitioners aware of the state of the art and the specificities of the most prolific studies. Furthermore, this paper also intends to clarify the project themes and tools most used in these works.

Originality/value

The geographical locations of influential articles and authors are revealed. Additionally, frequently used words are listed and helped to develop a research agenda that highlights relevant themes, methods and industries.

Human Resource Abilities and Skills in TQM for Sustainable Enterprises

Total quality management (TQM) is a lean manufacturing tool that focuses on ensuring the production of goods that meet design specifications and give customer satisfaction, both attractive benefits highly appreciated by managers. However, there are several factors involved in the success of TQM programs, many of which are cultural aspects associated with human resources (HR). This article presents a structural equation model that integrates three latent variables related to internal HR: “managerial commitment,” “employee integration,” and “training and education,” which are linked to the operational benefits of a manufacturing system. The variables are connected through six hypotheses that have been validated with information obtained from 398 responses of a questionnaire applied to manufacturing industry professionals. In addition, a sensitivity analysis was carried out to describe the probabilities of occurrence for the variables at low and high levels. The hypotheses were statistically validated with the partial least squared technique, where the results showed that human factors play an essential role in the success of TQM, since the direct, indirect, and total effects of managerial commitment, employee integration and training, and education processes on the benefits obtained from the implementation of TQM were statistically significant at 95% confidence.

Critical success factors for TQM implementation among manufacturing SMEs

Purpose

The purpose of this paper is to address a perennial question regarding the importance of soft total quality management (TQM) as part of the TQM implementation process – a topic that has been significantly understudied. Specifically, the authors address previous calls in the literature for stressing the soft aspects of TQM and for drawing a critical success factor (CSF) list that is formulated on the basis of empirical research instead of theory.

Design/methodology/approach

This is a comparative qualitative case study of three manufacturing SMEs combining empirical data from in-depth, semi-structured interviews with a large variety of stakeholders – from top managers to shop-floor workers, site visits and observations.

Findings

The study identifies 12 soft CSFs, and while most of these factors have been well-documented in the literature (e.g. top management involvement and leadership), the authors show evidence for the existence of other soft constructs that have not been considered or have been given little importance previously (i.e. middle management involvement and support, reward and recognition, CSR focus).

Research limitations/implications

The study fills two major gaps in the (T)QM literature. First, it enriches the understanding of TQM implementation among Japanese SMEs. Second, it addresses the importance of soft TQM as part of the TQM implementation process.

Practical implications

This paper provides company owners and managers with valuable knowledge that may assist their organisations in the pursuit of business excellence including higher product quality and employee satisfaction.

Originality/value

To the authors’ knowledge, this is the first (international) study to investigate TQM implementation within the context of Japanese SMEs.

A systematic review of Lean in healthcare: a global prospective

Purpose

Fostered by a rapid spread beyond the manufacturing sector, Lean philosophy for continuous improvement has been widely used in service organizations, primarily in the healthcare sector. However, there is a limited research on the motivating factors, challenges and benefits of implementing Lean in healthcare. Taking this as a valuable opportunity, the purpose of this paper is to present the key motivating factors, limitations or challenges of Lean deployment, benefits of Lean in healthcare and key gaps in the literature as an agenda for future research.

Design/methodology/approach

The authors used the secondary data from the literature (peer-reviewed journal articles) published between 2000 and 2016 to understand the state of the art. The systematic review identified 101 articles across 88 journals recognized by the Association of Business Schools ranking guide 2015.

Findings

The systematic review helped the authors to identify the evolution, current trends, research gaps and an agenda for future research for Lean in healthcare. A bouquet of motivating factors, challenges/limitations and benefits of Lean in healthcare are presented.

Practical implications

The implications of this work include directions for managers and healthcare professionals in healthcare organizations to embark on a focused Lean journey aligned with the strategic objectives. This work could serve as a valuable resource to both practitioners and researchers for learning, investigating and rightly adapting the Lean in the healthcare sector.

Originality/value

This study is perhaps one of the comprehensive systematic literature reviews covering an important agenda of Lean in Healthcare. All the text, figures and tables featured here are original work carried by five authors in collaboration (from three countries, namely, India, the USA and the UK).

R, P. A, Persis J, K.M. S. Industry 4.0: key findings and analysis from the literature arena

Purpose

In recent years, a new transformation known as Industry 4.0 has drawn much attention throughout the world, and numerous investigations have fundamentally looked into the uprising concept. However, few have concentrated on the literature review. Taking this as motivation, the authors endeavored to assess the different attributes of Industry 4.0. The paper aims to discuss these issues.

Design/methodology/approach

This review concentrated on linking the articles from different database and distinguishing the attributes of Industry 4.0. The authors assessed 85 articles from scholarly database and peer-reviewed journals on Industry 4.0 through the selection of the Mayring (2004) procedure. The examination included a four-advance process, in particular, material gathering, engaging investigation, classification of the choice and material assessment.

Findings

The study backs experts and readers to comprehend the spread of Industry 4.0 in various ventures. For academicians, this gives an extensive rundown of Industry 4.0 attributes. Besides, the writing review gives a chance to comprehend the idea of Industry 4.0 in detail. Further, the outcome aggregates the success factor, failure factor, business model, potential and difficulties in the context of Industry 4.0.

Research limitations/implications

Many areas such as supply chain, circular economy and healthcare have started exploring Industry 4.0. However, few specific cases have reported about it, and no generic model is found for real-time application.

Practical implications

The study serves as reference material for researchers and practitioners to understand the spread of Industry 4.0 and utilize the concept of Industry 4.0 for real-life application.

Originality/value

The study focuses on reporting the potential, challenges, business model and pre-requites of Industry 4.0.

V, Madhavan V, Gurumurthy A. Development of Lean Six Sigma training module: evidence from an emerging economy

Purpose

Nowadays, firms are keen on improving the quality culture in the organizations. The proven success of Lean and Six Sigma has given rise to the synergetic Lean Six Sigma (LSS) approach that has been catching fire in the past one decade. However, there exists a gap between the understanding and implementation of LSS in the organizations, especially in the emerging economies. Taking this as a valuable opportunity, the purpose of this paper is to present a development of LSS training module.

Design/methodology/approach

This study starts with a literature review of LSS to reinforce the understanding of the research subject in scope of manufacturing sector. Then, an online questionnaire was designed and used to collect responses from 181 companies located in the Indian sub-continent. Subsequently, the results obtained from the survey were analyzed using COARSE approach.

Findings

This study reveals two key findings and associated contributions. First, it was found that the overall awareness of LSS within the responded manufacturing firms is about 70.4 percent. Second, there is no single standard training module that exists in any of the sampled firms to cater to their quality programs. Hence, in order to improve the LSS awareness which could subsequently help managers as a resource for creating an efficient workplace, this paper presents a structured LSS training framework.

Research limitations/implications

Although this paper presents the importance of LSS and associated awareness level among the responded firms, more empirical evidence is required to generalize the model findings. Second, this study is scoped to firms that work out of the Indian sub-continent, and this provides a future opportunity to expand the scope of this research toward a global study for a comparison between emerging and developed economies. Third, this study is limited to manufacturing firms and hence paves an opportunity to research on a similar theme in services context as well.

Practical implications

Before embarking on an LSS journey, an organization can use the LSS training module proposed in this study to assess the employee awareness on LSS. Furthermore, organizations that already have a mature LSS practice can incorporate the LSS training module for periodic evaluation of the employees for effective change management.

Originality/value

The training module presented in this paper is the original contribution by the authors. This is no association to any single identifiable organization or associated funding. The direct practical implication of its application in real time is the value that managers could derive from the proposed LSS training framework.

V, Antony J. Assessment of Lean Six Sigma Readiness (LESIRE) for manufacturing industries using fuzzy logic

Purpose

Many organizations have reported significant benefits after the implementation of Lean Six Sigma (LSS). Embracing LSS requires asking some important questions: How Lean Six Sigma Readiness (LESIRE) can be measured? How can an organization identify the barriers for LESIRE? Answers to these questions are critical to both academicians and practitioners. The paper aims to discuss this issue.

Design/methodology/approach

This study illustrates the development process of a Lean Six Sigma Readiness (LESIRE) evaluation model to assess an organization’s readiness for LSS deployment using the fuzzy approach. The model was developed from 4 enablers, 16 criteria and 46 attributes of LSS, identified through a literature review.

Findings

To demonstrate the efficiency of the model, this study testing the LESIRE evaluation model in three Indian SMEs. Using experts’ ratings and weight, the researchers calculated the Fuzzy Lean Six Sigma index (FLSS) which indicates the LESIRE level of an organization and the Fuzzy Performance Importance Index (FPII) that helps to identify the barriers for LESIRE.

Research limitations/implications

The main limitations of this study are that it did not consider the failure factors of LSS for model development and the LESIRE was only tested in manufacturing industries. Thus, future researchers could focus on developing a model with failure factors. The results obtained from the SMEs show that LESIRE is capable of assessing LESIRE in an industrial scenario and helps practitioners to measure LESIRE for the future decision making process.

Practical implications

The LESIRE model is easy to understand and use without much computation complexity. This simplicity makes the LESIRE evaluation model unique from other LSS models. Further, LESIRE was tested in three different SMEs, and it aided them to identify and improve their weak areas, thereby readying them for LSS deployment.

Originality/value

The main contribution of this study it proposes a LESIRE model that evaluates the organization for FLSS and FPII for LESIRE, which is essential for the organization embarking on an LSS journey. Further, it improves the readiness of the organization that is already practicing LSS.