International Journal of Lean Six Sigma

Srinivasan, Kumar; Yadav, Vineet Kumar; Kumar, Anish; Margabandu, Balaganesh; Selvaraj, Janish; Kumar, Anshu

2023 International Journal of Lean Six Sigma

doi: 10.1108/ijlss-10-2021-0171

This paper aims to assist managers and food supply chain practitioners in efficiently implementing lean and green (LG) practices for sustainability. Examining barriers to LG practices, as well as prioritizing mitigation strategies in the food supply chain, are all part of this work.Design/methodology/approachUsing a combination of literature review and expert team inputs, this paper investigated the LG barriers and their solutions under PESTEL (Political, Economic, Social, Technological, Environmental and Legal) framework. To prioritize them, this work used the fuzzy best worst method (fuzzy BWM) with the fuzzy technique for order preference by similarity to ideal solution (FTOPSIS).FindingsFrom the fuzzy BWM, the economic barriers were identified as the most significant. From the FTOPSIS approach, top management expertise and commitment to adopting LG practices were identified as the best solution for overcoming the barriers.Practical implicationsThis paper discusses the barriers and solutions for successfully implementing LG techniques from the real-time food supply chain. The practitioners and food chain managers welcomed the methodology for its use in prioritizing the barriers to LG practices. Conclusions drawn from this work were found to be realistic.Originality/valueThe original contribution of this study is to present the model framework for barriers and solutions of LG practices in the dairy supply chain using the hybrid MCDM technique.

López-Manuel, Lucas; Sartal, Antonio; Vázquez, Xosé H.

2023 International Journal of Lean Six Sigma

doi: 10.1108/ijlss-04-2022-0091

The purpose of this paper is to evaluate how temporary labor moderates the relation between two well-known lean initiatives (process flow and process quality) and line productivity. This paper focuses on high-volume, low-variety (HVLV) shop floors, where work experience may not be as relevant as expected and extrinsic motivation of the temporary workforce could become a key driver of individual performance.Design/methodology/approachThe authors follow an insider econometrics approach based on panel microdata (1,793 observations) from nine lines over two years in a Spanish manufacturing plant. The authors selected this setting for two reasons: Spain has traditionally had one of the highest levels of temporary employment in the world, so it perfectly represents labor market trends in OECD countries. Simultaneously, the authors also searched for a type of shop floor that could be representative of one of the most common manufacturing environments: a shop floor with highly repetitive and low-complexity work tasks.FindingsThe results of this paper suggest that in HVLV environments, temporary labor could contribute up to a 1.4% improvement in line productivity, provided there is a strong lean implementation. Otherwise, the use of temporary labor could undermine the positive effects of both process flow and process quality on plant productivity.Originality/valueExternal incentives derived from high levels of unemployment, coupled with manufacturing’s increasing automation and specialization, may be minimizing the weaknesses traditionally associated with temporary workers in lean environments. By contrast, those shop floors lacking lean standards face serious productivity consequences from adjusting to global trends by using temporary work.

Simeão, Isaías; Ferreira, Karine Araujo

2023 International Journal of Lean Six Sigma

doi: 10.1108/ijlss-02-2022-0027

Despite the benefits provided by the implementation of the lean philosophy, the most recent research discusses whether the high degrees of efficiency obtained with the implementation this philosophy could contribute positively or negatively in current pandemic scenario. This study aims to analyze how resilient construction industry companies in Brazil were in the face of the COVID-19 pandemic, comparing the performance of construction companies with different implementation levels of lean construction.Design/methodology/approachThree case studies were carried out in construction companies in Brazil with different application levels of the lean philosophy.FindingsAmong the results obtained, greater resilience to face COVID-19 was verified in those with a higher implementation level of the lean philosophy. Additionally, it was found that the larger the size of the companies surveyed, the greater the level of implementation of the lean philosophy.Research limitations/implicationsDue to the state of pandemic, and the work carried out in the home office, contact with companies was restricted. In addition, few companies actually adopt the lean philosophy in the construction sector in Brazil. Most of companies use only a few lean construction tools in specific sectors. For the few others who actually implement the philosophy, the acceptance to participate in the research was low.Originality/valueThe lean construction is something very new and innovative for the construction sector in Brazil, and there is little evidence of its use. Few companies adopt the philosophy in the country, and many of them also did not experience such an impactful moment in their entire existence. Thus, the analysis of the relationship between lean construction and resilience in the civil construction sector in Brazil is something innovative.

Francisco, Marta Gomes; Canciglieri Junior, Osiris; Santanna, Angelo Marcio Oliveira

2023 International Journal of Lean Six Sigma

doi: 10.1108/ijlss-06-2022-0131

The Design For Six Sigma (DFSS) methodology is one of the most important to achieving excellence in an organization’s product development process. This paper aims to propose a roadmap for product development based on the DFSS for the consumer durables manufacturing industries. The proposed roadmap presents a systematic approach to the phases of the product development process, integrating the statistical techniques and quality tools that should be used in each phase.Design/methodology/approachThis study presents a detailed roadmap for product development, which was built by identifying gaps in the DFSS methods, based on previous studies on the subject. In this step, the opportunities are provided in all phases from creation to discontinuation of the product in the market. In addition, the roadmap presented was validated by team of stakeholders in the product development process of different industrial companies.FindingsThe proposed roadmap for the product development process based on six sigma design suggests a visual tool with sequential steps and techniques that allow you to follow the evolution of the development process from idea conception until the product is discontinued in the market. Identifying the priorities of organizations, especially the consumer, regarding the quality and reliability of the product.Practical implicationsThe roadmap seeks to facilitate an understanding of the important stages of the product development process and to provide an approach to improving and optimizing the product before the manufacturing process step through the principles of DFSS methodology. This research provides a guide step by step to apply statistical techniques and quality tools in the product development process to achieve high quality and six sigma level in the manufacturing process.Originality/valueThe proposed roadmap of this research combines design for sigma and product development concepts, covering a wide spectrum of relevant activities that include the product development process, the application of statistical techniques and the design of high-quality durable consumer goods to match manufacturing technologies.

Hoque, Imranul; Maalouf, Malek Miguel; Tanha, Moutushi; Islam, Md Shamimul; Alam, Mohammad Zahedul; Sarker, Moniruzzaman

2023 International Journal of Lean Six Sigma

doi: 10.1108/ijlss-05-2022-0103

This study aims to explore the challenges in implementing and sustaining lean in garment supplier factories and the buyer–supplier role in mitigating lean barriers in a typical situation and pandemic.Design/methodology/approachFollowing a qualitative research approach and multiple embedded case study method, data were collected through in-depth interviews with senior managers of one lead buyer and their four key garment supplier factories in Bangladesh. Within and cross-case analysis, techniques were applied to understand the context-oriented lean challenges and buyer–supplier role in mitigating the challenges.FindingsThe study findings demonstrate that garment suppliers are less prepared and unsystematic in lean implementation having limited capabilities and less preparation. Moreover, they have limited support from buyers, less commitment from top management and employee resistance to implementing lean. Lean challenges become more intense because of the COVID-19 pandemic. However, buyer–supplier responsible, cooperative and collaborative behaviour can mitigate lean challenges.Research limitations/implicationsWhereas many stakeholders may be responsible for lean challenges, this study explores dyadic role between buyer and supplier only based on a single lead buyer and their four suppliers. Hence future studies could consider more buyers and suppliers for a holistic understanding.Practical implicationsThis study could help buyers and suppliers understand the underlying causes of lean implementation challenges in garment supplier factories and their role in sustaining lean reducing the challenges, particularly in a pandemic.Originality/valueTo the best of the authors’ knowledge, for the first time, this study depicts how buyer and supplier can play their due roles to mitigate lean challenges in garment supplier factories in a pandemic situation.

Ahmed, Selim; Hawarna, Shatha; Alqasmi, Ibrahim; Ashrafi, Dewan Mehrab; Rahman, Muhammad Khalilur

2023 International Journal of Lean Six Sigma

doi: 10.1108/ijlss-05-2022-0102

This study aims to investigate the mediating role of lean management on the relationship between workforce management and value-added time in private hospitals. This study also investigates the direct influences of workforce management and lean management on the value-added time of the hospitals.Design/methodology/approachThis study applied a quantitative approach to obtain data from the private hospitals’ staff in Peninsular Malaysia. A self-administered survey questionnaire was used to collect data from 287 hospital staff using a stratified random sampling method. The partial least squares structural equation modeling (PLS-SEM) approach was used to determine the internal consistency, reliability, validity of the constructs. The PLS-SEM method was also used to test the hypothesised research model via SmartPLS 3.3.4 version.FindingsThe findings of the study indicate that lean management has a direct and significant effect on the value-added time of private hospitals. The findings also revealed that lean management significantly mediates the relationship between workforce management and value-added time in private hospitals. The analysis of the results indicates that both workforce and lean management have a significant impact on the value-added time of the hospitals.Practical implicationsThis study provides empirical contributions to enhance the quality of workforce management, lean management and value-added time. The findings of this study provide valuable insights into how effectively managing the workforce and providing guidelines to augment the lean management practices can ensure value-added time in Malaysian hospitals and the overall health-care industry. The lean management framework provides useful insights for the policymakers to understand the significance of workforce management, lean management on ensuring value-added time through reducing waiting times, unnecessary delays, generating a higher degree of patient safety, satisfaction and loyalty.Originality/valueThe research findings provide some essential indications for the health-care service providers to understand how the lean management approach can be implemented to enhance value-added time and how lean management can play a mediating role in creating a link between workforce management and value-added time in hospitals. This study also contributes to the theoretical and practical perspectives. The present study contributes to a better understanding of workforce management and lean management in health-care sectors from theoretical and practical perspectives.

Doyer, Ilse; Bean, Wilna L.

2023 International Journal of Lean Six Sigma

doi: 10.1108/ijlss-03-2022-0057

The purpose of this paper was to develop a quantitative classroom observation method that is able to analyse the school day to identify Time-on-Task losses comprehensively and systematically, at a level of detail that can be used by teachers and principals to stimulate and focus practical improvement efforts.Design/methodology/approachThe novel Time-on-Task Analysis (TOTA) model was developed by triangulating the conceptual framework of the Overall Equipment Effectiveness metric with the semantics and structure of the target domain. Once developed, the model was tested structurally against a time-series classroom observation data set, after which the resulting TOTA was presented to a sample of 52 education stakeholders, who then gave their perspectives of the analysis in a structured survey.FindingsThe ontological model was found to be accurate, complete and without conceptual incongruencies, and its output novel and useful by the sample of education stakeholders. Of the participants, 90.3% found the analysis to provide a new perspective, 94.2% reported that the analysis triggered improvement ideas and 80.8% thought that their school(s) could benefit from a TOTA study.Originality/valueThe TOTA model introduces a time-loss-focused perspective to the field of quantitative classroom observation studies, which is dominated by more sociologic- and pedagogic-focused topics. Its grounding in Overall Equipment Effectiveness also gives it a more detailed and systematic approach than the few Time-on-Task studies done to date, resulting in a model made for the “Gemba”: the school classroom.

Trubetskaya, Anna; McDermott, Olivia; Brophy, Padraig

2023 International Journal of Lean Six Sigma

doi: 10.1108/ijlss-08-2022-0169

This study aims to propose a tailored Lean Six Sigma framework providing an accessible Lean Six Sigma methodology for compound feed manufacturers with the aim of mitigating rising costs and increasingly complex demands from customers.Design/methodology/approachA Lean Six Sigma framework was designed combining Lean value stream mapping and Six Sigma structured problem-solving with a case study in an Irish compound feed manufacturer.FindingsThe study found that the Lean Six Sigma implementation framework provided a simplified approach, which fitted the resource availability within compound feed manufacturing.Research limitations/implicationsThe study is limited by the constraints of a sole case study in providing empirical evidence of the effectiveness of the framework. Nevertheless, a conceptual Lean Six Sigma model is proposed, which will assist compound feed manufacturers implementing a continuous improvement approach.Originality/valueThis paper proposes a simplified approach to the implementation of Lean Six Sigma in agricultural compound feed manufacturers and in small and medium-sized organisations. This is the first such study in Ireland and will add to the body of work on Lean in agriculture and aid other agri-businesses and compound feed manufacturers in understanding how Lean Six Sigma can benefit.