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A Feasibility Study For Six Sigma Implementation in Turkish Textile Smes
A Feasibility Study For Six Sigma Implementation in Turkish Textile Smes
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Article in South East European Journal of Economics and Business · April 2012
DOI: 10.2478/v10033-012-0006-6
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This paper aims to investigate the Critical Success Factors (CSFs) for the successful introduction of Six Sigma in
Small and Medium Sized Turkish Textile Enterprises. A survey-based approach is used in order to identify and
understand the current quality practices of Small and Medium Sized Enterprises (SMEs). CSFs and impeding
factors are identified and analyzed. The involvement and commitment of top management, linking quality
initiatives to employee and information technology and innovation are found to be important CSFs for textile
SMEs. The leadership and commitment of top management, strategic vision, and data collection and
measurement, are found to be the most CSFs for the successful introduction of Six Sigma, whereas the lack of
knowledge of the system to start the initiative and the presence of ISO-certification in the company are found to
hinder its implementation. The lack of qualified personnel and incompetence with new technologies are found to
lower the performance of Turkish textile SMEs.
1. Introduction
In the intensity and pace of today’s cutthroat business across the industrial spectrum from shop floor personnel
world, many large organizations have sought strategies to the senior management level in the organizations
such as TQM, balance scorecard, ISO-certification and Six which have embraced it. The companies which have
Sigma to improve process and product quality. Since the invested in and implemented Six Sigma (i.e., allocated a
early 90’s, numerous global organizations have special budget to launch it and created a separate
undertaken the implementation of Six Sigma organizational culture), have been rewarded with
methodologies which seek to improve yield and reduced operational costs and defect rates, achieved high
productivity through the identification and elimination of rates on business profits, increased employee morale, and
defects, mistakes or failures in business processes or improved the quality of their final product. In addition to
systems by concentrating on the more important aspects these, customer loyalty and Return on Investment (ROI)
of production as seen by their customers. (Snee, 2004; have also shown measurable improvement (Antony et al.,
Antony, 2008). 2005; Kumar et al., 2006, 2008; Snee, 2004).
The implementation of Six Sigma extends way beyond The importance of Six Sigma as a business strategy
the industries of manufacturing and services, to has recently been recognized by SMEs as their
government, the public sector, healthcare and non-profit * Mehmet Tolga Taner
organizations (Antony et al., 2005; Montgomery, 2005; Üsküdar University, Üsküdar, Istanbul, Turkey
Pande et al., 2000; Pyzdek, 2003; Breyfogle, 1999). The E-mail: mtaner@uskudar.edu.tr
relevance of Six Sigma has been successfully proven
April 2012 63
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A Feasibility Study for Six Sigma Implementation in Turkish Textile SMEs .
understanding of Six Sigma’s ability to address supply SMEs. Customer focus, communication, cultural change,
chain issues (Antony et al., 2005, 2007). Keller (2003) and education and training, rewards and recognition, shared
Snee and Hoerl (2003) have stated that Six Sigma can understanding of core business processes, resource
offer many SMEs the same benefits as larger commitment, understanding of Six Sigma methodology;
organizations. In the Turkish context, however, Turkish and project prioritization and selection have also been
SMEs have yet to follow the lead given by large and indentified as significant factors (Antony et al., 2005,
institutionalized Turkish organizations, as it seems that 2007; Kumar, 2007; Spanyi and Wurtzel, 2003; Waxer,
they have yet to be convinced of the benefits of the 2004).
implementation of Six Sigma (Antony et al., 2005, 2008; The single most important factor in the successful
Antony, 2008; Harry and Crawford, 2004; Kumar, 2007). deployment of Six Sigma is found to be the combination
Lack of a formalized strategy, operational focus, limited of management involvement and commitment (Kumar,
managerial and capital resources, and misconception of 2007). Kumar’s study also shows that the lack of resources
efficiency measurement are the characteristics which and poor training/coaching are the two most important
distinguish the SMEs from larger organizations (Brouthers impediments in the successful deployment of Six Sigma.
et al., 1998; Fuller-Love, 2006; Garengo et al. 2005; Kumar and Antony (2010) have found that strong
Ghobadian and Gallear, 1997; Hudson et al., 2001; Hussein leadership and management commitment are the critical
et al., 1998; Jennings and Beaver, 1997). factors in the successful implementation of Six Sigma in
While there is ample evidence to support the success the UK SMEs.
of Six Sigma in many large corporations, there is still a CSFs are those factors that play an essential role in
need for documented evidence in SMEs. The evidence leading to the success of any organization, since if the
which does exist on Six Sigma implementation in SMEs is objectives associated with these factors are not met, the
based on quality management practices in SMEs, which in organization will inevitably fail (Rochart, 1979). Thus, this
turn are based on consultants/ practitioners experience paper investigates the CSFs for the successful
and are not of sufficient depth and volume. (Antony et al., introduction of Six Sigma in Turkish textile SMEs.
2005 and 2008; Kumar, 2007; Kumar and Antony, 2008;
Wessel and Burcher, 2004). 2. Turkish SMEs and Six Sigma
Using a sample of SMEs in Germany, Wessel and
Burcher (2004) have identified the specific requirements Constituting one of its major parts, SMEs are the
for implementation of Six Sigma. Similarly, Antony et al. backbone of the Turkish economy. While the integration
(2005, 2007) have assessed the current status of Six Sigma of Turkey to the EU is progressing, the business
implementation in UK SMEs and shown that many of the environment and performance of the Turkish SMEs are
SMEs show a lack of awareness. In addition, these becoming more important. With the acceptance of EU’s
companies do not have the resources available to Basel-II framework, Turkish SMEs are expected to foster
implement Six Sigma projects. Likewise, a case study on entrepreneurship, competition, innovation and growth
Six Sigma implementation in a UK manufacturing SME by means of access to more financial resources.
brought to light a cost-effective approach of eliminating The regional rather than global focus of Turkish SME’s
the critical-to-quality issue (Thomas and Barton, 2005). Six remains one of their major drawbacks. To attain more
Sigma application in an Indian SME has also proven share in international markets, they should primarily work
successful in improving their delivery rates (Darshak and on their core competencies, focus more on marketing,
Desai, 2004 and Desai, 2006). Recently, Timans et al. human resources, new technologies, innovation and
(2011) implemented Lean Six Sigma in Dutch SMEs. environmental values, and most importantly
Improvement in on-time deliveries, labor efficiencies continuously improve their manufacturing processes to
and annual profits have been among the other areas lower scrap rates and increase efficiency rates.
which have been shown to benefit SMEs when Six Sigma Turkish SMEs are in the earliest stages of
has been successfully implemented (Gupta and Schultz, implementing Six Sigma. Turan et al. (2008) states that
2005). Antony et al., (2005, 2007), Kumar (2007), Spanyi Turkish SMEs readily accept implementing the TQM tools
and Wurtzel (2003), Waxer (2004) have demonstrated that and/or ISO but are still reluctant to introduce the Six
strong leadership and senior management commitment Sigma concept. In fact, the use of ISO can be beneficial to
are crucial to successful Six Sigma implementation in SMEs before embarking on Six Sigma (Kumar et al., 2008).
64 SEE Journal
A Feasibility Study for Six Sigma Implementation in Turkish Textile SMEs .
To achieve this, Turkish SMEs should maintain a higher of Six Sigma implementation, CSFs represent the essential
quality of thought. The factors hindering the introduction ingredients without which SMEs performance stands little
of Six Sigma in Turkish textile SMEs are investigated in chance of success (Kumar et al., 2009).
this paper. The questionnaire was emailed to 100 randomly
selected Turkish SMEs operating in the textile industry.
2.1. Interview with an A-class Turkish Textile Twenty-eight SMEs returned the questionnaire. This
Company resulted in a response rate of 28%. Six of these SMEs
(21.4%) were small-sized enterprises and 22 of them
(78.6%) were medium-sized (Figure 1).
A face-to-face interview with the CEO of Company-A
The respondents of the survey consisted of CEOs,
revealed the following facts about the industry.
managing directors and quality managers. The responses
Company-A is one of the most successful SMEs
reveal that 17.85% of the SMEs (5 out of 28) implemented
specializing in manufacturing towels and bathrobes in
only the ISO certification. The results show that all the
the Turkish textile industry. However, it has not
SMEs under study have quality departments and that
implemened any quality initiative in the past. There are a
their employees are trained for quality.
total of 225 employees working in the SME, including five
engineers. The SME has a quality department. All
employees are trained for quality. The CEO believes in the
benefits of CI and is open to implementing Six Sigma in
the SME to decrease the scrap rates in their
manufacturing process as the company has been
suffering from high rates of 15.07%, 17.48% and 13.44%
in 2009, 2010 and 2011, respectively. Following assistance
from a Swiss consultancy company, structural
improvements have been realized. A French company
named SGS periodically continues auditing the SME’s
quality standards.
The current quality control practice of the SME is as Figure 1: Histogram showing the number of employees for the SMEs
follows. Inspections are made daily during the under study
manufacting process. Errors are classified into groups
such as stains, (mildew, fluff, penmarks, oil stains), holes, 3.1. Analysis
tears, folding errors, printing smudge, dying
inconsistency, sewing error, fastener error (e.g. missing, The respondents of the survey were asked to shortlist
damaged, misplaced), joining error, elastic too three factors out of seven alternatives available that
loose/tight/torn, size error, bridging error, etc. Each error mostly define the organization’s strategic objectives.
group also has subcategories for different sections of the They were then asked to give information regarding the
garment. Next, the number of scrap pieces (i.e. pieces quality initiatives deployed in the past and present. After
with error) is recorded. Finally, error rates are calculated this they were asked to rate the importance of 26 CSFs
and reported weekly to the top management. necessary for and 5 impeding factors hindering the
introduction of Six Sigma as a quality initiative in their
3. Methodology and Data SMEs. Finally, they were asked to rate the 7 possible
reasons lowering the performance of their SMEs. The
In this study, a survey-based approach is used to respondents made use of the Likert scale of 1 to 5 while
identify the continuous improvement (CI) initiatives rating the importance of CSFs, e.g. a rating of 1
commonly practiced in Turkish textile SMEs as well as corresponding to “not important at all”, 2 corresponding
understanding the approach of these SMEs to Six Sigma. to “not important”, 3 corresponding to “neither important
The 15-item questionnaire was tailored to Turkish textile nor not important”, 4 corresponding to “important”, and
SMEs requirement from Kumar et al. (2009) with the 5 corresponding to “very important”. Consequently, the
purpose of identifying the CSFs for implementing Six ratings are collected and averaged.
Sigma in Turkish SMEs (See the Appendix). In the context
April 2012 65
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A Feasibility Study for Six Sigma Implementation in Turkish Textile SMEs .
Table 1 summarizes the factors defining the strategic CEOs are satisfied with the status quo. Those SMEs (23 out
objective(s) of the Turkish textile SMEs. Profitability of 28, i.e. 82.14%) which have not undertaken any quality
(100%), flexibility (71.43%) and quality (53.57%) are the initiative, expressed interest in learning more about Six
three most important factors which the SMEs in this study Sigma.
have taken into account while deciding their strategic Turkish textile SMEs were asked to identify the top
objectives. three inhibiting factors that were felt to be barriers to
quality initiative implementation. Table 3 shows that
Strategic Objective Count % 64,29% of the responding enterprises stated that internal
Profitability 28 100% resistance was the most common factor in the SMEs. This
Flexibility 20 71.43% was followed by lack of knowledge and lack of top
management commitment.
Quality 15 53.57%
Lower costs 13 46.43%
Reasons for not implementing quality
Count %
Higher market share 8 28.57% initiatives
Internal resistance 18 64.29%
Innovation 0 0%
Lack of knowledge 15 53.57%
Other 0 0%
Lack of top management commitment 12 42.86%
Availability of resources 11 39.29%
Table 1: Factors defining the strategic objective (s) of the Turkish textile Changing business focus 10 35.71%
SMEs
Inadequate process control techniques 9 32.14%
Poor employee participation 6 21.43%
Lack of training 5 17.86%
66 SEE Journal
A Feasibility Study for Six Sigma Implementation in Turkish Textile SMEs .
CSF
Question Mean Rating Standard Deviation Rank
rated the effect of the CSF as above average. The three The majority of the SMEs have stated that they are
most important CSFs cited across the SMEs are found to hesitant to implement Six Sigma due to a lack of
be the involvement and commitment of top knowledge of the system to start the initiative (4.714) and
management (4.571), linking quality initiatives to the presence of the ISO-certification (3.214) in the
employee (4.536) and information technology and company. The two most important CSFs lowering the
innovation (4.464). The three most common important performance of SMEs are found to be lack of qualified
CSFs cited across the SMEs for succesful introduction of personnel (4.536), and incompetence with new
Six Sigma are found to be the leadership and technologies (4.464). To test internal consistency,
commitment of top management (4.786), strategic vision Cronbach’s alpha values were calculated for each
(4.750), and data collection and measurement (4.714).
April 2012 67
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A Feasibility Study for Six Sigma Implementation in Turkish Textile SMEs .
performance measure. All the Cronbach’s alpha values are to be equally perceived by the SMEs as the fifth
showed satisfactory levels (above 0.7). benefit.
68 SEE Journal
A Feeasibility Study for Siix Sigma Implementaation in Turkish Textile SMEs .
lack
l of a databbase developeed specifically addressing th he Garenggo, P., Biazzo, S. and Bititci, U. (2005), Perfformance
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Internation
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a their person nnel are not co ompetent eno ough to manag ge
Ghobadian, A. and Gallear, D. (1997), TQ
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a work with the foreign so oftware currently at hand. Thhis Internation
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p andd have not givven the required importancce Gupta, P. and Schultz, B. (2005), Six Sigma Success in Small
to
t information n technologies.. Businesses,, Quality Digest, April 5, 2005.
The resultss also reveal thhat the compaanies are awarre Hudson n, M., Smart, P.A. and Bourne, M. (2
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d practice
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o the cross-functional teamwork within th he organization. in SME peerformance measu urement systems, International Joournal of
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1
Aside
A from thhis, data collecction and measurement an nd
Hussein, M., Gunasekaran, A. and Laitinen n, E.K. (1998), Management
regular
r audits are also indisp
pensible. Thesee show that thhe accounting
g system in Finnish
h service firms, Tecchnovation, 18, 57
7-67.
SMEs
S are mentally ready forr implementing g Six Sigma, yeet
Jennings, P. and Beaaver, G. (1997), The performan nce and
still
s need to be e more fully in
ntroduced to its benefits. Thhis competitivee advantage of small firms: A management
m perrspective,
can
c be accomp plished by presenting worksshops to the to op Internation
nal Small Business Journal, 15, 63-75.
management
m h textile SMEs by qualified Six
of the Turkish Jeyaramman, K. and Teo, L.K. (2010), A conceptual
c framework for
Sigma
S consulttants who arre well-versed d in the textile critical succcess factors of lean Six Sigma: Implementation on the
performancce of the elecctronic manufaccturing service industry,
industry.
i
Internationnal Journal of Lean
n Six Sigma, 1, 3, 19
91-215.
The major limitation of th his study was the number (2 28
Keller, P. (2003), Does Six Sigma workk in Smaller Commpanies?,
out
o of 100) of Turkish textilee SMEs that responded to th he Available from
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q . Future studiees should focuss on performinng http://wwww.qualityamerica.ccom/knowledgece
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T SMEss operating iin different industries an nd Kumar,, M. (2007), Succcess Factors and Hurdles to Six Sigma
Implementtation: the case ofo a UK manufaccturing SME, International
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u g the impact of industriall variability on o
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successful
s impplementation o of Six Sigma.
Kumar,, M. and Antony, J. (2009), Investigating the e quality
managemeent practices in Six Sigma agaainst Non-Six Sig gma UK
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A Feasibility Study for Six Sigma Implementation in Turkish Textile SMEs .
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d. Linking Quality Initiatives to Employee
e. Linking Quality Initiatives to Customer
Appendix f. Linking Quality Initiatives to Business
g. Linking Quality Initiatives to Supplier
The questionnaire used in the study is given below. h. Project selection
i. Project management skills
1. Which of the following is the most important j. Information Technology and innovation
strategic objective of your SME? Please choose k. Communication
the three most applicable. l. Cultural change
a. Profitability m. Education and training
b. Flexibility
c. Quality 8. In your opinion, what are the factors hindering the
d. Higher market share implementation of a quality initiative in your SME? Please
e. Innovation choose the three most important.
f. Lower costs a- Availability of resources
g. Other (Please state) b- Lack of knowledge
c- Lack of training
2. How many employees are working in your SME? d- Internal resistance
Please state. e- Poor employee participation
f- Inadequate process control techniques
3. How many engineers are employed in your SME? g- Changing business focus
Please state. h- Lack of top management commitment
4. Is there any quality department in your SME? 9. In your opinion, what is the importance of the
Yes/No following factor for successful introduction of Six Sigma
in your SME? Please rate 1 to 5.
5. Are the employees trained for quality? Yes/No a. Leadership and Commitment of top
management
6. Which quality initiative(s) has your SME b. Strategic vision
implemented in the past and present? Please c. Change management
state the ones applicable. d. Commitment of middle managers
a. Six Sigma e. Funds and Resources
b. TQM f. Education and training
c. Lean
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A Feasibility Study for Six Sigma Implementation in Turkish Textile SMEs .
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