Six Sigma in a low volume and
complex environment
Denyse Julien and Phil Holmshaw
Cranfield School of Management, Cranfield University, Cranfield, UK
Abstract
Purpose – The purpose of this paper is to understand how the full potential of the global
phenomenon “Six Sigma” can be realised in low volume, high complex manufacturing.
Design/methodology/approach – The research reported on in this paper is based on a case study
company – ComplexCo plc. A questionnaire to gauge user perceptions about the tools and techniques
was used, combined with interviews with five master black belts (MBB) which were conducted as part
of the study. The usefulness and the frequency of use of common Six Sigma tools and techniques as
deployed in low volume complex manufacturing was gauged and also the identification of the key
challenges faced during Six Sigma deployment in ComplexCo are explored.
Findings – The analysis clearly shows that the difficulty in acquiring data is restricting the use of
analytically biased tools during the analyse phase of DMAIC (Define Measure Analyse Improve
Control). It was also evident, through all stages of DMAIC, that the “softer” tools are deployed more often
and the usefulness rank higher than for the “harder” tools. Finally an alternative to the traditional DPMO
metric was developed called “% Right First Time”.
Research limitations/implications – The paper is based on a single case study company and so
the results from the study are not currently widely generalisable.
Originality/value – There is a lack of literature available which explores the deployment of
Six Sigma in low volume, high complex manufacturing environments. This paper contributes to the
body of knowledge through the establishment of adaptations, which both ComplexCo and other
organisations can use to successfully deploy Six Sigma programmes in low volume and high complex
manufacturing.
Keywords United Kingdom, Six Sigma, Manufacturing industries, Low volume manufacture, DMAIC,
Complex products, Tools
Paper type Case study
1. Introduction
The work reported on in this article is based on a case study at one of the leading
providers of power systems and services globally; ComplexCo. ComplexCo has been
committed to an extensive programme of improving performance across its operating
units for several years at the time of writing this article. The deployment of Six Sigma
tools was considered as central to this improvement journey, however, due to the
complexity of the products and the low volumes this has not been without many issues.
This article explores the perception and challenges of some key users in ComplexCo
of various Six Sigma tools. The greatest successes with Six Sigma have tended to be in
high volume applications, where key process/product characteristics can be identified
and design of experiment results realised quickly, the experiments can be highly
iterative which enables the businesses to gain control of the processes in short
timescales. This however was not the case in ComplexCo with annual production
volumes of the many facilities ranging from between one and 300 units per year. This
coupled with the complex processes, setups and huge variety of components involving
The current issue and full text archive of this journal is available at
www.emeraldinsight.com/2040-4166.htm
IJLSS
3,1
28
International Journal of Lean Six
Sigma
Vol. 3 No. 1, 2012
pp. 28-44
q Emerald Group Publishing Limited
2040-4166
DOI 10.1108/20401461211223713