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Requirements, Challenges and Impacts of Lean Six Sigma Applications - A Narrative Synthesis of Qualitative Research
Requirements, Challenges and Impacts of Lean Six Sigma Applications - A Narrative Synthesis of Qualitative Research
Requirements, Challenges and Impacts of Lean Six Sigma Applications - A Narrative Synthesis of Qualitative Research
https://www.emerald.com/insight/2040-4166.htm
IJLSS
12,2 Requirements, challenges and
impacts of Lean Six Sigma
applications – a narrative
318 synthesis of qualitative research
Received 17 June 2019 Mohamed Alblooshi and Mohammad Shamsuzzaman
Revised 10 September 2019
16 February 2020
Department of Industrial Engineering and Engineering Management, College of
7 March 2020 Engineering, University of Sharjah, Sharjah, United Arab Emirates
Accepted 22 April 2020
Michael Boon Chong Khoo
School of Mathematical Sciences, Universiti Sains Malaysia, Penang, Malaysia
Abdur Rahim
Faculty of Business Administration,
University of New Brunswick, Fredericton, Canada, and
Salah Haridy
Department of Industrial Engineering and Engineering Management, College of
Engineering, University of Sharjah, Sharjah, United Arab Emirates and
Benha Facility of Engineering, Benha University, Benha, Egypt
Abstract
Purpose – The purpose of this paper is to identify, present and categorise the main requirements,
challenges and impacts of Lean Six Sigma (LSS) applications. Emphasis is given to the soft impacts of LSS
applications, which are intangible in nature and difficult to quantify and measure, highlighting the most
frequently cited ones.
Design/methodology/approach – A qualitative synthesis of the studies using the narrative synthesis
approach is adopted to descriptively summarise and categorise the requirements, challenges and impacts of
LSS applications. The studies were searched by using the following keywords: “LSS applications,” “LSS
requirements,” “LSS challenges” and “LSS impacts” in almost all major electronic databases such as Emerald,
Taylor and Francis, ScienceDirect and Wiley. A total of 116 articles published between 2007 and 2017 in 41
academic journals were collected and reviewed. Consideration was also given to a number of substantial
publications in 2006, 2018 and 2019.
Findings – In addition to its process efficiency and financial impacts, LSS was found to have another impact
category related to individual and organisational behaviours. Management commitment, training and
organisational culture were concluded to be amongst the most important and required categories for successful
LSS applications. It was also found that the lack of awareness of LSS tools and benefits and the lack of change
management and resistance to change were amongst the most cited categories of implementation challenges.
Research limitations/implications – The studies published between 2007 and 2017 are mainly
considered in this paper. It is believed that 10-year publication period considered in this research is sufficient to
1. Introduction
This study explores and identifies the soft aspects of the impacts of Lean Six Sigma (LSS)
applications and their requirements and challenges by providing a closer and deeper look at
previous research. In addition to the financial and marketing impacts that have been proven
for LSS, there are impacts that are neither direct financial impacts nor direct marketing
impacts. Such impacts are called the intangible impacts and are often referred to as the soft
impacts of LSS that are hard to quantify and measure (Johnstone et al., 2011). The study is
divided into four main sections. Section 1 provides a brief description of Lean, Six Sigma
(SS) and LSS. In addition, a summary of existing literature reviews on LSS is provided.
Section 2 presents the methodology of the research, highlighting search strategy, narrative
synthesis methodology, descriptive analysis and patterns of publications and data analysis
where publications have been discussed and reviewed in detail. In Section 3, the collected
information is analysed and categorised, highlighting the most often cited LSS
requirements, challenges and impacts. Finally, Section 4 provides concluding remarks.
Reference Purpose
Muraliraj et al. (2018) Enhanced the understating of LSS by summarising past and present
research trends highlighting gaps and future research opportunities
Sunder et al. (2018) Reviewed literature on LSS applications in the service industry to
construct a morphological framework and identify research gaps and
future research opportunities
Lande et al. (2016) Reviewed articles on LSS CSFs in the manufacturing and service
industry
Deblois and Lepanto (2016) Looked into continuous improvement approaches of Lean and SS in
the acute care industry by conducting a systematic literature review
Mason et al. (2015) Looked into the application of LSS in surgical processes by reviewing
a number of articles published in medical databases
Abu Bakar et al. (2015) Worked on a literature review of the CSFs of LSS focussing on prior
implementation readiness factors
Assarlind et al. (2013) Introduced new factors of importance for successful LSS application
Albliwi et al. (2014) Systematically reviewed a number of papers on LSS critical failure
factors
Albliwi et al. (2015) Identified important themes of LSS applications in the manufacturing
sector by systematically reviewing a number of journal papers
Zhang et al. (2012) Assessed the status and the maturity of LSS application
Yadav and Desai (2016) Systematically reviewed a number of articles on quality improvement
by analysing them from the dimensions of year of publication, journal,
country, research design and type and application sector
Sreedharan and Raju (2016) Reviewed LSS literature from the aspect of its definition,
demographics, methodologies and industries
Raval et al. (2018) Reviewed a number of LSS articles by providing insights on its
current state and other dimensions
Singh and Rathi (2018) Reviewed literature on the benefits and challenges/critical barriers of
Table 1. LSS implementation in the health care, HR, financial and education
Summary of existing sectors
LSS literature review Prasanna and Vinodh (2013) Analysed the literature on LSS implementation in SMEs discussing
papers the type of research, benefits and frameworks
medium enterprises (SMEs) was provided by Prasanna and Vinodh (2013), focussing on Lean Six
research type, benefits achieved and frameworks. Sigma
Table 1 below summarises and highlights the purposes of the existing LSS literature
review papers discussed above:
applications
An analysis of existing LSS literature review papers reveals a number of limitations and
research gaps that researchers who plan to conduct similar reviews should note and take
into consideration. For example, many of the literature review papers discussed were limited
to only articles that contained “Lean Six Sigma” in their titles or as a keyword (Muraliraj
323
et al., 2018; Raval et al., 2018; Singh and Rathi, 2018). It should also be noted that most of the
articles reviewed were academically based and lack practitioners’ input (Raval et al., 2018).
In addition, only commonly used and most reputable databases such as Emerald,
ScienceDirect, SpringerLink, Taylor and Francis, Elsevier, Google Scholar and Inderscience
were used for the search process, which may have limited the content variety and the
number of articles reviewed (Muraliraj et al., 2018; Raval et al., 2018; Singh and Rathi, 2018;
Sreedharan and Raju, 2016; Yadav and Desai, 2016). In terms of geographical scope, most of
the articles reviewed were concerned only with developed countries such as the USA and the
UK, where most of the publications originated from, but not with developing countries
(Muraliraj et al., 2018; Yadav and Desai, 2016). We may also notice that all of the literature
review papers discussed were published after the year 2012. Sreedharan and Raju (2016)
highlighted that organisations lack guidance on implementation of LSS as a synergised tool
and Zhang et al. (2012) mentioned that LSS is still at an elementary stage. This makes it very
obvious that the research on LSS as an integrated tool is a relatively new research area that
is not yet well researched compared to the research on Lean only or SS only.
It was observed that there are not many comprehensive, broad and detailed reviews
covering all LSS-related aspects and dimensions, as most of the studies focussed only on its
process and implementation (Raval et al., 2018). There is also a lack of justification of the
sustainability of LSS benefits other than enhancing financial outcomes, process excellence
and customer satisfaction. For example, it was mentioned that LSS promotes radical and
incremental types of innovation and it is hard to find studies that provide evidence on
whether such an impact or other kinds of hidden impacts as classified by Raval et al. (2018)
do actually exist and if they continue (Muraliraj et al., 2018). Similarly, Sunder et al. (2018)
recommended further investigation of the impact of LSS applications on innovation,
organisational culture and its learning capacities and employee satisfaction. A good number
of articles highlighted the need for categorising and understanding the priorities of LSS
requirements, enablers and barriers across various sectors (Muraliraj et al., 2018; Raval et al.,
2018; Singh and Rathi, 2018; Sreedharan and Raju, 2016; Yadav and Desai, 2016).
Consideration of cultural, work and other contextual factors while studying the mentioned
LSS aspects was also highlighted as a future research direction (Muraliraj et al., 2018; Raval
et al., 2018; Sreedharan and Raju, 2016).
Hence, there is a need to provide more in-depth knowledge to justify the importance of
LSS as an integrated tool and to identify and prioritise its different kinds of impacts,
implementation success requirements and barriers. Unlike all of the previous LSS literature
reviews that either focussed on a certain LSS aspect in specific contexts, countries and
sectors or dealt only with the categorisation of LSS literature, the objective of this paper is to
highlight and categorise the soft impacts of LSS applications along with its implementation
requirements and challenges as experienced in a variety of sectors and countries, both
developed and developing, which makes this research a valuable contribution to both
academics and LSS practitioners.
IJLSS 2. Methodology
12,2 2.1 Search strategy
The research work started with a planning stage based on the predefined research objective
where a number of key journals and key search terms such as LSS applications, LSS
requirements, LSS challenges and LSS impacts were identified. Only accessible, full text
academic journal articles from almost all major electronic databases such as Emerald,
324 Taylor and Francis, ScienceDirect and Wiley published between 2007 and 2017 were
considered in this paper. It is believed that 10-year publication period considered in this
research is sufficient to study the evolution, benefits, limitations and future trends of a
particular research topic. Similar timeframes were followed in many other literature review
studies such as Sunder et al. (2018), who considered 12-year period (2003-2015), Lande et al.
(2016), who covered 15-year period (2000-2015) and Albliwi et al. (2015), who reviewed a 13-
year period (2000-2013). In addition, a few relevant articles that focusses on requirements,
challenges and/or impacts of LSS applications published in 2006, 2018 and 2019 were also
considered. Even though these articles were not published within the 10-year timeframe
specified in this research, they were cited as they discuss interesting aspects related to the
applications of LSS in service industry and its critical success requirements. The
aforementioned databases are reputable and reliable. They are commonly used as rich
databanks with a wide variety of journals in different fields including engineering and
quality management as highlighted by Muraliraj et al. (2018) and Yadav and Desai (2016).
Previous literature review studies by many authors such as Sreedharan and Raju (2016),
Sreedharan et al. (2018) and Singh and Rathi (2018) used similar databases. The keywords
and the search terms used for the search process were very specific, covering certain aspects
of LSS. It is worth mentioning that not only articles on LSS applications were reviewed, as in
previous literature review papers but also articles on the application of Lean only or SS only
were considered. As a result, the number and the contents of the articles collected provided a
very inclusive overview of the research subject, covering a variety of sectors and countries.
Books, conference papers, websites, reports and other grey literature were excluded. Articles
that were not related to the search domain or did not contain the key search terms specified
were also not considered. An electronic search using the aforementioned inclusion and
exclusion criteria was conducted and a list of more than 200 articles was initially identified,
then filtered based on the title and abstract to exclude non-relevant articles and finally the
list was narrowed down to 116 articles. The shortlisted articles were descriptively analysed
and their contents were reviewed to categorise the information targeted to be collected.
Figure 1 illustrates the literature review research methodology followed in this paper.
- Exclude non
relevant articles
with reason
based on title or
abstract
25
20
No. of Publications
15
10
Figure 2.
Distribution of
0 articles by year of
2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019
publication
Year of Publication
IJLSS publications in 2006, 2018 and 2019. Referring to Figure 2, 2014 was a boom year for LSS
12,2 publications regarding the areas covered in this study (i.e. requirements, challenges and
impacts), followed by the years 2015, 2016 and 2012 that had 15, 13 and 13 publications,
respectively. A possible reason for the significant jump in the number of LSS publications in
the year 2014 is the increase in the popularity of the topic and the acceptance it began to
receive by both old and new journals as a rich subject for academics and practitioners. In
326 years 2007, 2008 and 2011, there were limited publications contributing to this field,
compared to the years 2009, 2010, 2013 and 2017. The review also included two articles
published in 2006 and 2019 along with five articles published in 2018.
2.3.2 Distribution of articles by research area. Even though there were some articles that
covered more than one research area, each article was categorised and listed under only one
research area that it was most closely related to and fit the best. A total of seven research
areas were identified as follows:
Application impacts: direct application of the well-known LSS tools and analysis of
their impacts.
Framework development: development of LSS implementation roadmap and guide.
Application challenges: difficulties and obstacles faced during the implementation of
LSS.
General review: general highlights about LSS tools.
Future trends and research opportunities: future of LSS and how it may evolve.
Relationships: valuable relationships that LSS has with other factors and variables.
Application success factors: requirements for a successful deployment of LSS tools.
As illustrated in Figure 3, 59% of the publications were in the area of application impacts, as
it is the most comprehensive topic and usually covers the other aspects of the research areas
mentioned, followed by publications that provided a general review of the research topic,
which constituted 12% of the total number of the publications reviewed. Publications about
framework development and application success factors made up 10% and 7%,
Framework
development
10% Application impacts
59%
General review
Figure 3. 12%
Distribution of
articles by research
area
respectively, of the total reviewed publications. Publications related to future trends and Lean Six
research opportunities and relationships amounted to 6% of the total publications reviewed, Sigma
3% each. Similarly, publications about application challenges were 6% of the total number
of the publications. Despite this classification and for the purpose of this research, the
applications
articles were analysed and discussed from the perspective of LSS applications’
requirements, challenges and impacts.
2.3.3 Distribution of articles by journal name. The articles reviewed were extracted from
a total of 41 journals from various aspects including quality, management sciences,
327
engineering management, business, technology, manufacturing, health care, construction,
marketing, supply chain and performance management disciplines. The largest numbers of
articles were published in three journals named International Journal of Quality and
Reliability Management, International Journal of Productivity and Performance
Management, and Journal of Manufacturing Technology Management. Other leading
journals in terms of publications reviewed were TQM and business excellence, the TQM
journal and International Journal of Operations and Production Management. Figure 4
illustrates the contribution from each journal.
2.3.4 Distribution of articles by paper type. In terms of the paper type and given the
nature of the search terms used, most of the publications reviewed were research papers.
There were also a number of case studies of various approaches: brainstorming, site visits,
observation, project, action research, survey and interview based. A literature review paper
was the approach used in nine articles. Other types of papers included conceptual,
viewpoint, general review and technical papers. Figure 5 shows the different paper types of
the reviewed publications.
2.3.5 Distribution of articles by application sectors. Based on application sectors, there
were 26 publications from the manufacturing sector, which made up a large portion of the
publications. That is in line with the fact the LSS was started in the manufacturing sector
and that its applications were more popular in manufacturing-related fields. Other sectors
where LSS is popular are higher education (HE) and health care and the classification of the
12,2 80
70
60
328
No. of publications
50
40
30
20
10
Figure 5. 0
Distribution of Research paper Case study Literature Conceptual Viewpoint General review Technical
review paper paper
articles by paper type
Research method
publications revealed that there were 22 articles in these sectors. Some of the other sectors
covered were service, call centres, financial, supply chain and logistics, public, construction,
corporate communication, food, HR, tourism, textile and apparel, telecom, policing,
technology, aerospace, airline and hospitality as illustrated in Figure 6.
2.3.6 Distribution of articles by tools used. Although the study is about LSS as an
integrated approach, publications about Lean only or SS only were considered as well, based
30
25
No. of publications
20
15
10
Figure 6.
Distribution of
articles by
application sector
Application sector
Continuous
Improvement, 1%
Lean Six
Sigma
applications
Six Sigma, 21%
329
Lean Six Sigma, 57%
Lean , 21%
Figure 7.
Distribution of
articles by tools used
on the assumption that whatever is applicable for Lean and SS individually can be
generalised to LSS. As shown in Figure 7, LSS publications contributed to 57% of the
publications reviewed, followed by publications about either Lean or SS applications, each
of which contributed to 21% of the publications reviewed. A number of publications about
continuous improvement were reviewed as well, amounting to only 1% of the total reviewed
publications.
itself must be identified at very early stages before the implementation starts (McLean and
Antony, 2014). Risk categories associated with the implementation of Lean were identified
and classified by Marodin and Saurin (2015). Three groups of risks were identified as
follows: management of the process, top and middle management support and shop floor
involvement. Amongst the three aspects, it was found that the management of the process
has the greatest number of risks including lack of motivation, lack of knowledge and
communication and difficulties in visualising the perceived benefits.
Aboelmaged (2011) identified 47 barriers to SS implementation, examples of which are
resistance to change, intangibility and sometimes uncertainty of the results, weak
presentation of SS findings, lack of awareness about SS value, poor knowledge about LSS
tools and its application, no cross-functional teams, lack of top management support, lack of
supportive organisational structure, the presence of some social and psychological aspects
that are hard to be controlled, etc. The identified barriers were categorised to seven barrier
factors, of which it was found that knowledge and support barriers, referred to as soft
barriers because of their intangible nature, were the ones reported to be the most challenging
barriers to overcome.
In the HE sector, LSS was found to be less popular than in other sectors. Antony et al.
(2012) stated that LSS terminologies that were originally developed for the manufacturing
sector did not fit the HE context and the perception that LSS provides fast and quick results
could be wrong or exaggerated. The culture of HEIs might not support the openness needed
for adopting LSS because of the lack of understanding the various customer types involved:
students, faculty, admin staff, etc., not linking LSS project objectives with customers and the
organisational overall strategy, lack of a proper communication plan that would ensure
alignment of all teams’ efforts and lack of resources in terms of budget and time. Antony
et al. (2018) found that lack of management support, lack of understanding of LSS
methodology and its applicability in the context of HE processes, the organisational culture
of HEIs that is highly based on academic autonomy and constrained by other government
regulations and the sustainability of LSS impacts were amongst the most critical challenges
to LSS applications.
Although Lean was very effective in US hospitals and did actually improve medical care
processes, there were some challenges faced during the implementation such as the lack of
leadership and the failure to understand the concept of Lean. A study by Grove et al. (2010)
discussed the challenges faced during the implementation of Lean in the health service
sector in the UK. When it comes to understanding Lean concepts, it was found that it will
Reference Challenges of LSS applications
Lean Six
Sigma
McLean and Antony (2014) Lack of motives and wrong expectations applications
Misunderstanding of the requirements of application
Marodin and Saurin (2015) Risks associated with process management
Aboelmaged (2011) Resistance to change
Lack of top management support
Lack of supportive organisational structure 335
Unleashed SS business strategy
Lack of knowledge and complexity of the tools
The intangible nature of the results
Lack of cross functional teams
Antony et al. (2012) The culture of HE that does not fit LSS terminologies
Lack of management support and commitment
Lack of process thinking and ownership
Lack of understanding the various customer types
Not linking LSS project objectives to customers and organisational overall
strategy
Lack of a proper communication plan
Lack of resources
Antony et al. (2018) Lack of management support
Lack of understanding of LSS methodology
Organisational culture of HEIs
Sustainability of LSS impacts
Grove et al. (2010) Lack of leadership support
Lack of understanding the principles of Lean
Krueger et al. (2014) Poor project selection
Failing in approaching LSS as a cultural change
Timans et al. (2014) Lack of resources Table 3.
Grima et al. (2014) Being impatient for the results Summary of the
Kumar et al. (2011) Lack of understanding of the tools challenges of LSS
Not linking project objectives with organisational goals applications
Laureani et al. (2010) showed that the application of LSS can help in increasing the efficiency
of operations in a call centre through better utilisation of human and technical resources,
which as a result will help reduce the running cost and employee turnover. It also helped in
344 identifying the sources of errors and even beyond, that to cover aspects related to the
reasons why customers contact call centres. The DMAIC approach was applied to improve
the first call resolution rate and the results were positive, as the percentage of unresolved
enquires after the first call dropped. The success of the project strengthened the
management’s awareness of the applicability of LSS concepts in the call centre context and
improved employees’ communication, involvement and understanding of the process. In
addition, a culture of continuous improvement was promoted. The inbound call process,
which is a customer calling to submit a claim request for resolution where an automated
menu system is used to reroute calls to the concerned department, was studied by Piercy
and Rich (2009a, 2009b) as the average time for closing a customer request was too long. The
application of Lean enabled staff to better understand customer requirements and to become
more aware of the inbound call process in terms of what contributes to its success and
brings value to customers. The process was redesigned and a number of unnecessary steps
were eliminated to speed up the process, better serve customers and reduce costs associated
with rectification works. In another study by Gupta et al. (2016), Lean applications in call
centres enabled the staff to better understand the process and eliminate all sources of waste.
It reduced the time to complete a customer enquiry which helped in serving more customers,
cutting costs and achieving saving targets. It also helped in increasing the first-call
resolution ratio and reducing operator turnover. Examples of other benefits are as follows:
Enabling capacity expansions without additional facilities.
Increasing productivity and operational performance.
Improving understanding of demand and its relationship with resources and
supply.
Establishing a culture of continuous improvement.
Reducing variability and defects.
Improving quality and efficiency.
3.3.9 Multi sectors. Antony et al. (2019) presented a case study for organisational learning
drawn from LSS applications in Scottish policing services. One of the LSS applications in
policing services was applying DMAIC tools to improve consistency of occupational health
services provided to employees, which led to reducing the number of rejected referrals and
resulted in reduced contract costs, better utilisation of managers’ time and high employee
attendance rates. Another example was the application of DMAIC to review the typing
processes for developing reports such as prosecution reports and civilian witness
statements. LSS was useful for improving current performance, enhancing report quality,
reducing report preparation waiting time, allocating staff efficiently and freeing up their
time to focus on other value-adding activities. A third application was using the Lean
approach to streamline and standardize the sick pay process, which is directly related to
police staff wages and workload to reduce labour costs in the sick pay process. A number of
benefits were obtained, including establishing a standardized and clear process
implementation and eliminating organisational overpayment risk. In general, LSS resulted
in eliminating barriers between functional departments, increasing employee engagement Lean Six
and morale, and deriving incremental process innovation in many processes related to Sigma
policing services.
Wickramasinghe and Wickramasinghe (2016) examined the effects of continuous and
applications
incremental improvement efforts on job performance of shop floor employees in textile and
apparel firms and the role that Lean played in mediating this relationship. Job performance
is an organisational variable that can be described by the job-related and non-related soft
and hard competencies such as communication skills, demonstrating efforts and 345
cooperation, behaviours and attitude and supervision and leadership skills. Lean is a
journey that requires a change in the organisational culture and its social structure, and
therefore organisations have to adopt new work and behaviour-related habits and practises
as part of the Lean implementation process. It was found that the continuous improvement
influenced the job performance.
An exploratory study of the implementation of Lean construction techniques in
sustainable construction was carried out by Ogunbiyi et al. (2014). Lean construction is a
philosophy that is based on continuous improvement efforts, elimination of waste, value
creation, customer and process focus, improved communication and relationships,
management of projects and supply chain. Sustainable construction is simply achieving
sustainability in built assets through the integration of environmental protection, social
well-being and economic prosperity aspects into construction-related processes. That can
increase customer satisfaction, provide some flexibility with respect to adapting to any
natural or social changes and use resources efficiently. Some of its environmental benefits
are reducing utility consumption and improving water and air quality. The economic
benefits are not limited to decreasing operational cost and increasing sales price. Some of its
community-related benefits are enhancing occupant’s comfort, reducing liability and
improving health and safety in the working environment. In addition to the previously
mentioned benefits of sustainable construction, Lean construction and sustainability can
increase competitiveness through better utilisation of resources, reducing costs and
enhancing quality. Using Lean construction tools can help in reducing accident rates and
waste, boosting efficiency and quality, achieving cost saving in utilities consumption
and improving environmental quality. The results of this study showed that improving
corporate image and reputation was the most important benefit of integrating Lean
construction and sustainability, mainly using just-in-time, value analysis, daily huddle
meeting and visualisation tools. Other benefits were obtaining a competitive advantage,
improving process flow and meeting customer expectations. Ullah et al. (2017) provided
another case for implementing SS in the construction industry. SS was introduced to the
construction industry as a means for reducing cycle time, errors, defects and control
variations. It was found that the industry is facing some challenges concerning project
quality level and delivery, as industry practitioners tend to follow traditional methods and
avoid adopting techniques such as LSS. Amongst the reported benefits, it was found that
LSS can enhance organisational reputation and image in addition to its financial benefits.
A case study for the application of LSS to HR function and an investigation of its role in
improving HR-related activities was reported by Laureani and Antony (2010). HR refers to
the process of managing people in an organisation, starting with attracting talent and
ending with separation to achieve business objectives. That includes personnel
administration matters and all other interactions between an employee and the organisation
through the employee’s life cycle. The study was for the purpose of reducing voluntary
turnover in a large multinational service company. The application of LSS achieved a 10%
reduction in turnover, and a cost saving of US$1.3m annually, which proves the
IJLSS effectiveness of LSS in administrative processes. LSS can be also applied to reduce the costs
12,2 and time of new hires and administrative errors related to employee benefits, leaves, etc.
Indian industries, which are challenged by global competitiveness and operational
continuous improvements, need to sustain business in such conditions. A number of tools
are being used for this, however, results have shown their ineffectiveness in achieving the
expected improvement and it was found that SS is not fully explored and adopted by
346 organisations in the sector. Regarding this, Antony and Desai (2009) provided an overview
of the status of SS adoption in the Indian industry. SS helps leaders change the culture of
their organisations by providing them with the required tools and strategy. Based on the
survey results, the drivers for implementing SS were mainly enhancing operational
excellence, increasing customer satisfaction and sustaining competitive advantages.
Nabhani and Shokri (2009) showed that the application of SS in a food distribution
enterprise resulted in a 40% reduction in the number of causes of defects (from 34 to only 20
defects per week) and a 60% reduction in customer complaints about late delivery, which
was reflected in a financial benefit of GBP 30,000 for the company. Other internal intangible
impacts improved job satisfaction amongst shop floor employees due to the better flow of
goods, which made the execution of tasks easier. Some of the other goals for applying SS in
food distribution enterprises are reducing the delivery lead time and therefore providing
faster delivery, reducing the loading time, which will help in achieving higher level of
customer satisfaction, and maximizing value for shareholders.
Table 4 below summarises the impacts of LSS applications with respect to each sector
collected from the list of articles reviewed:
4.1.1 Requirements of Lean Six Sigma applications. There were many requirements and
success factors for LSS applications that can be categorised as follows:
Management commitment: the support provided by management, their Lean Six
involvement, engagement and belief in LSS. Sigma
Organisational culture: an infrastructure that facilities the implementation process. applications
Resource availability: mainly financial resources and time allocation.
Training: the aspects of knowledge management, information sharing, technical
knowledge of the tools and necessary soft skills.
Change management: organisational willingness and capability to introduce, apply
355
and manage a change.
Strategy: to link the LSS project objectives to the organisational strategy and
customers.
Communication: to ensure a consistent awareness level of the status of the LSS
projects across the organisation through effective communication plans.
Teamwork: employee involvement, their behaviours and attitudes, as well as the
level of collaboration between departments.
Project management: the selection criteria of projects and the way they are
managed.
As illustrated in Figure 8, the most cited LSS requirements were management commitment,
training and organisational culture. Next, teamwork and change management, which are
regarded as requirements for successful LSS journey. Communication and project
management were factors that were relatively less important compared to strategy.
Resource availability was the least important factor amongst the ones identified in the
research. The implementation of LSS is thus facilitated by a number of organisational and
human-related contextual factors that should be assessed prior to implementation so that
necessary improvement actions are taken to ensure smooth execution of LSS activities.
4.1.2 Challenges of Lean Six Sigma applications. Challenges of LSS applications can be
categorised as follows:
Lack of management support: lack of management’s buy-in of the concept of LSS,
which results in very low level of commitment towards it.
Resource availability
4%
Project management
6%
Communication
7%
Management
commitment
22%
Strategy
8%
Change management
9%
Training
18%
Figure 8.
Teamwork Categories of the
10%
Organisational culture
requirements of LSS
16% applications
IJLSS Lack of awareness: poor understanding of LSS methodology and tools, which is also
12,2 associated with lack of training on necessary hard and soft skills.
Lack of change management and resistance to change: not having a clear LSS
deployment plan and neglecting the role of culture and change management in the
implementation process.
Lack of tools: unavailability of resources such as human, technical and financial.
356 Intangibility and unsustainability of the results: benefits from the value of LSS
adoption are not directly perceived by all employees.
Lack of communication: poor communication of the objectives, status and other
updates of LSS project, resulting in no alignment of employees’ efforts across the
organisation.
The weightage of each category of LSS applications challenges based on the frequency of citation
is illustrated in Figure 9. Lack of awareness and lack of change management and resistance to
change were the two most frequently cited challenges, which can be overcome by training and
change management, which were amongst the most cited requirements for successful LSS
projects. Lack of management support was also amongst the most common challenges, which
clearly reflects the important role of management in LSS implementation. Lack of tools was
found to be a barrier to LSS implementation, especially in SMEs. The intangibility and
sometimes the unsustainability of LSS results was also identified as a challenge that would
require a proper communication plan to increase the awareness of LSS outcomes.
4.1.3 Impacts of Lean Six Sigma applications. The observed impacts of LSS applications
can be categorised as follows:
Industrial impacts: industry-specific processes and their associated key performance
indicators (KPIs) (e.g. student waiting time in counselling centres in the HE sector,
Lack of
communication
5%
Intangibility and
unsustainability of
the results
10% Lack of awareness
27%
Lack of tools
16%
Lack of change
Lack of management management and
resistance to change
Figure 9. support
25%
Categories of the 17%
challenges of LSS
applications
energy usage in the manufacturing sector, radiology throughput in the health-care Lean Six
sector, etc.). Sigma
Organisational impacts: the way the organisation operates and functions, as well as applications
its structure, culture, image, learning, competitiveness, innovation level, reward
system and change adaptability (e.g. changing organisational hierarchy, providing
knowledge for facilitating change, promoting continuous improvement culture, etc.).
Individual impacts: the utilisation of individuals and the way they interact and deal 357
with each other, and their overall satisfaction, motivation, empowerment knowledge
and morale levels (e.g. better utilisation of staff, improving human management,
staff empowerment, etc.).
General impacts: the general and common impacts based on LSS definition,
experienced by most organisations who adopt LSS (e.g. increasing sales, reducing
costs, increasing customer satisfaction, etc.).
Figure 10 illustrates the weightage of each LSS application impact category based on the
frequency of citations in the published studies. It is noted that organisational impacts were
the second in terms of popularity after the general LSS impacts that were the most frequent
impacts, followed by industrial and individual impacts. It is interesting to note that
organisational impacts are mostly intangible in nature and that individual impacts received
considerable research attention. These observations are valuable and confirm the existence
and importance of the intangible impacts of LSS, as most of the organisational and
individual impacts are of an intangible nature.
Table 5 below provides a summary of the research findings highlighting the
requirements, challenges and impacts of LSS applications ranked in terms of their
importance, based on the frequency of citations, from the most to the least important.
Individual impacts
17%
General impacts
35%
Industrial impacts
24%
Figure 10.
Organisational impacts Categories of the
24% impacts of LSS
applications
LSS applications Findings
IJLSS
12,2 Requirements Management commitment (22%) The support provided by management,
their involvement, engagement and belief in
LSS
Training (18%) The aspects of knowledge management,
information sharing, technical knowledge of
the tools and necessary soft skills
358 Organisational culture (16%) An infrastructure that facilities the
implementation process
Change management (9%) Organisational willingness and capability
to introduce, apply and manage a change
Teamwork (10%) Employee involvement, their behaviours
and attitudes, as well as the level of
collaboration between departments
Strategy (8%) To link the LSS project objectives to the
organisational strategy and customers
Communication (7%) To ensure a consistent awareness level of
the status of the LSS projects across the
organisation through effective
communication plans
Project management (6%) The selection criteria of projects and the
way they are managed
Resource availability (4%) Mainly financial resources and time
allocation
Challenges Lack of awareness (27%) Poor understanding of LSS methodology
and tools, which is also associated with lack
of training on necessary hard and soft skills
Lack of change management and Not having a clear LSS deployment plan
resistance to change (25%) and neglecting the role of culture and
change management in the implementation
process
Lack of management support Lack of management’s buy-in of the concept
(17%) of LSS which results in very low level of
commitment towards it
Lack of tools (16%) Unavailability of resources such as human,
technical and financial
Intangibility and unsustainability Benefits from the value of LSS adoption are
of the results (10%) not directly perceived by all employees
Lack of communication (5%) Poor communication of the objectives,
status and other updates of LSS, resulting
in no alignment of employees’ efforts across
the organisation
Impacts General impacts (35%) The general and common impacts based on
LSS definition, experienced by most
organisations who adopt LSS (e.g.
increasing sales, reducing costs, increasing
customer satisfaction, etc.)
Organisational impacts (24%) The way the organisation operates and
functions, as well as its structure, culture,
image, learning, competitiveness,
Table 5.
innovation level, reward system and change
Summary of the
research findings (continued)
Lean Six
LSS applications Findings
Sigma
adaptability (e.g. changing organisational applications
hierarchy, providing knowledge for
facilitating change, promoting continuous
improvement culture, etc.)
Industrial impacts (24%) Industry-specific processes and their
associated KPIs (e.g. student waiting time 359
in counselling centres in the HE sector,
energy usage in the manufacturing sector,
radiology throughput in the health-care
sector, etc.)
Individual impacts (17%) The utilisation of individuals and the way they
interact and deal with each other and their
overall satisfaction, motivation, empowerment
knowledge and morale levels (e.g. better
utilisation of staff, improving human
management, staff empowerment, etc.) Table 5.
and perceived quality. A distinction between the two approaches could be in the scope of
application, as Lean deals with the entire organisational value chain, whereas SS is focussed
on specific projects and processes within the organisation. This paper discussed three main
aspects of LSS applications – requirements, challenges and impacts – following a narrative
synthesis approach. A descriptive analysis of studies published between 2007 and 2017 was
provided that highlighted main research trends, followed by a comprehensive review of each
publication. A number of requirements, challenges and impacts of LSS applications were
collected and categorised.
The literature review shows that management commitment, training and organisational
culture were found to be the most important requirements for successful LSS projects. On
the other hand, lack of awareness, lack of change management and resistance to change and
lack of management support were common challenges to successful LSS projects. The
impacts of LSS applications were categorised to industrial impacts, organisational impacts,
individual impacts and general LSS impacts, and the review of previous studies provided
evidence and created an awareness for the importance of organisational impacts being
amongst the most cited impacts, and that LSS does have individual impacts as well.
This literature review provides a holistic overview of LSS application while focussing on
the soft aspects of its impacts that were not deeply discussed in previous studies. We believe
that this paper will contribute to both academia and practical fields, as the information
collected in this literature review will serve as a source of reference for LSS practitioners
who wish to become more exposed to LSS applications in various sectors and improve their
understanding about it and for academics who might be interested in carrying out further
research in this regard.
Based on the descriptive analysis and patterns of publications, it was observed that there
were few studies about LSS applications published in the Middle East, East Asia, North
Africa and Europe. In addition, the observations about the requirements, challenges and
impacts of LSS applications were based on single case studies that were also limited to
specific sectors in confined geographical areas. Furthermore, little attention was paid to
considering organisation size – large versus small, the level of complexity of the processes
being studied and the application of LSS as a combined tool. That limits the generalisation
of the observations to wider, more extensive and cross-sector populations.
IJLSS Hence, future research should be conducted in studying larger, cross-sectional and
12,2 geographically broader organisations adopting similar or different approaches of the studies
reviewed in this paper, as it will be an interesting step forward to check if the observations
about LSS applications collected in this study can be generalised to other sectors. On the
other hand, it might also be worth digging into and focussing on specific industries to better
understand LSS impacts on organisations and individuals. Furthermore, the LSS impacts
360 discussed were only the positive ones that benefit the organisation and it would be
interesting to consider the other point of view. A promising research area could be checking
LSS practitioner and expert feedback on the observations collected about LSS applications.
It is also noted that there is a need for carrying out further research about how
organisations can improve their preparedness for LSS implementation by providing them
with roadmap and framework that can assist them in meeting different LSS requirements so
that they can overcome the challenges of LSS implementation. It is also necessary to find
some ways to quantify the impacts of LSS, especially the organisational and individual
impacts that are of intangible nature and also make use of them in improving other
organisational aspects such as innovation.
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Corresponding author
Mohammad Shamsuzzaman can be contacted at: mshamsuzzaman@sharjah.ac.ae
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