Luis Rocha-Lona

Lean and Green – Synergies, Differences, Limitations, and the Need for Six Sigma

Historically, profitability and efficiency objectives have been the prevailing interest for organisations. However, the move towards green operations has forced companies to seek alternatives to combine these with green objectives and initiatives. Green lean is the result of this combination. The purpose of this paper is to critically discuss the green lean approach and the potential benefits of integrating Six Sigma to enhance its effectiveness. The paper is based on a literature review that discusses the synergies and differences of lean and green, and its main limitations. Departing from the limitations identified, the paper then proposes Six Sigma, and specially its problem solving methodology DMAIC, as an approach that may help in overcoming the limitations of green lean. Thus, the paper conceptually proposes Green Lean Six Sigma. It intends to offer academics, researchers and practitioners interested in lean and green with some initial conceptual ideas regarding their possible integration with Six Sigma.

Investigating the green impact of Lean, Six Sigma and Lean Six Sigma: A systematic literature review

Purpose The academic literature and research lines exploring the effect of quality improvement methods on environmental performance still remain in early stages. The purpose of this paper is therefore to investigate, through a systematic review of the existing academic literature, the environmental (green) impact of using quality and operations improvement methods such as Lean, Six Sigma and Lean Six Sigma. This includes the impact on energy saving and the usage of natural resources. Design/methodology/approach This study follows a systematic literature review approach through which it analyses research papers published in top 16 operations and quality management journals. No specific time frame was established, but a set of keywords were used to short-list the articles. A sample of 70 articles was finally short-listed and analysed to provide a discussion on environmental concerns related to Lean, Six Sigma and Lean Six Sigma. Findings The comprehensive review of short-listed articles indicates that both Lean and Six Sigma can be considered effective methods to support the conservation of resources, combat global warming and saving energy. Various scholars provide evidence of this, and as such, organisations should not only consider these methods to manage quality and improve operational performance but also meet environmental regulations. A set of research questions that demands further investigation has also been proposed based on the findings of this research. Research limitations/implications This study is limited to a sample of 70 articles collected from top 16 operations and quality management journals. The search of journals is also limited to a set of key words (“Lean”, “Green”, “Six Sigma”, “environment”, “sustainable” and “sustainability”) used to short-list the sample size. Practical implications The study shows that organisations can consider the adoption of Lean, Six Sigma and Lean Six Sigma to meet environmental regulations, save costs and also meet quality management standards. This will contribute in helping organisations to formulate more effective and inclusive strategies which do not only consider the quality and operational dimensions but also the environmental dimension. Originality/value Literature exploring the environmental/green impact of quality management methods commonly used in industry is limited. There is also a lack of studies aiming to investigate the green impact of Lean and Six Sigma in top operations and quality management journals. The study focusing on investigating the green impact of Lean, Six Sigma and Lean Six Sigma methods altogether is also a research first of its kind.

An analysis of managerial factors affecting the implementation and use of overall equipment effectiveness

To ensure manufacturing organisations remain competitive, most of them are turning to total productive maintenance (TPM) and lean manufacturing to ensure seamless operations. Overall equipment effectiveness (OEE) is the foundation of these two business improvement strategies as it tackles the underlying losses that impede equipment efficiency. This study presents the prevalence of managerial issues related to the implementation and use of OEE in the manufacturing industry. To do this, five hypotheses and four research questions were formulated and tested using a combination of descriptive statistics and cross-tabulation, chi-square, analysis of variance, Tukey’s pairwise comparison, Z-test and correlation tests. Data were collected through a survey questionnaire responded by 139 manufacturing organisations worldwide. The results establish, among other ‘soft’ aspects, the linkage of the OEE implementation with that of TPM and lean manufacturing, and the drivers, most critical factors, barriers and the role of management in its implementation. The study also identifies how manufacturing organisations employ the information provided by OEE and how the data for its computation are collected. This study supports the very limited empirical research on the implementation and use of OEE. Thus, this research provides organisations, and their managers, with a better understanding of different factors that affect the successful deployment and management of this highly used measure in industry.

A conceptual framework for the implementation of quality management systems

Some evidence suggests that Quality Management Systems (QMSs) make a positive contribution towards the competitiveness of organisations. However, evidence also suggests that organisations find their implementation difficult, and in many cases they are unsuccessful. This paper presents a conceptual framework that systematically guides organisations through a five-stage process to effectively implement and/or improve their QMSs and core business processes. The framework can be modified or amended to be adapted to the needs of specific industries and organisations. The paper discusses some of the main issues associated with the implementation of QMSs and summarises some of the frameworks and models that have been suggested for this purpose. Then, the paper explains, in detail, all the stages and activities of which the proposed conceptual framework consists. This papers main contribution consists of the proposal of an alternative and novel approach for the implementation/improvement of QMS and business processes.

Personal development review (PDR) process and engineering staff motivation

Purpose – The academic literature and motivational theory recognise the positive role of motivation on organisational performance and considers personal development as a key motivational factor. In practice, most organisations employ a Personal Development Review (PDR) process to drive and plan the development of their staff. This paper investigates the interrelation and impact of the PDR process, and its elements, on staff motivation. Design/methodology/approach – The study is based on a case study research approach carried out in two large manufacturing-engineering departments of a world-class manufacturing organisation. A survey questionnaire was designed, validated and distributed to the engineering staff and its results were analysed using descriptive statistics. Findings – The study’s results indicate that in most of the cases, a PDR process does not by itself motivate staff. But it argues that a poorly designed and conducted PDR process may make motivation, through personal development, difficult to achieve. Practical implications – This paper provides manufacturing managers with an opportunity to understand whether a common business process (i.e. PDR), and the elements that comprise it, can be employed as a method to aid in the motivation of their staff. Original value – This research expands the current knowledge on motivational and manufacturing management theory by performing an initial and exploratory study that establishes the impact of the PDR process on staff motivation. It is among the very first investigations that correlate the PDR process and motivation, especially in the manufacturing industry.

A Multi-Agent Architecture Framework to Improve Wine Supply Chain Coordination

Over the last few decades, a rapid advancement in the arena of technology has escalated the competitive scenario across the globe. Several companies are now using intelligent systems to assist their supply chain management activities. This research, therefore, attempts to explore the advantage of using intelligent systems in managing supply chain activities. A review of the literature shows that with growing demand of food products, improved supply and storage facilities, and strong emphasis on cross boundary trade and policies have generated a lot of interest among researchers to look at the issues faced in the food supply chain. Researchers have attempted to study various types of food supply chains; however, little emphasis has been given to study the wine supply chain industry. One of the key challenges that exist in wine supply chain is the integration among the key members of the supply chain to accomplish a collective set of tasks. This paper, therefore, aims to address the supply chain coordination issue. To achieve better coordination among the wine supply chain members, this paper put forward the use of an intelligent agent based architecture framework. The paper suggests that the proposed intelligent multi-agent framework can reduce the complexity of decision making process, improve the supply chain coordination, and assist the SCM managers in smooth running of the wine supply chain.

Exploring the application of quality improvement programmes and ISO standards in the Indian marble mining sector

In this era of globalisation, as competition intensifies, providing quality products and services has become a competitive advantage and a need to ensure survival. To ensure such competitive advantage, organisations of different industries around the world have implemented several quality improvement programmes like ISO, TQM and Six Sigma. This paper explores the application of quality improvement programmes in the marble mining industry of India. A questionnaire survey was designed, validated and distributed to 52 Indian marble organisations. A total of 35 responses were obtained and analysed using descriptive statistics. Then, since the literature review and preliminary results of the questionnaire indicated ISO as the most popular quality improvement approach in this sector, an exploratory case study was conducted in Indias leading marble mining company to gain more in-depth information about the application of ISO in this particular industrial sector. The results revealed that the marble mining industry of India lacks far behind in relation to other industries of this country, with ISO 9000 being the most popular quality improvement approach. The results also provide evidence of the degree of awareness, implementation issues and results achieved through the ISO implementation in this industry.

Service innovation and performance in Mexican service SMEs

This empirical research investigates the influence of service innovation on the performance of service SMEs, especially within the context of a country with an emerging economy as it is the case of Mexico. Data were collected through a survey instrument designed and distributed among service SMEs in the Aguascalientes state of Mexico to test a hypothesis formulated from the literature review conducted. The instrument was validated using Confirmatory Factor Analysis, Cronbach’s alpha test and the Composite Reliability Index to ensure its reliability. The hypothesis was tested using structural equation modelling (SEM) using an as input 308 valid responses obtained from the survey. In general, the results obtained show that service innovation has a positive and significant effect on the performance of service SMEs. Specific research related to service innovation in service SMEs is limited. This paper therefore fills this research gap by expanding the limited body of knowledge in this field.

Lean Six Sigma Supply Chain Case Study: Aircraft Shipment Improvement in a Pharmaceutical Company

Distribution is an important activity in the integrated supply-chain management for pharmaceutical products, especially when these goods have to travel long distances from manufacturing facilities to the consumer markets. This paper presents the case of a pharmaceutical company in which the quality assurance and the management teams set an objective of reducing their distribution costs to less than 0.16 Euros per unit. The quality assurance (QA) team has decided to optimize sample shipments as a high priority in order to reduce costs. The methodology used in this study was supported through a series of experiments using a Lean Six Sigma approach that implemented the Define Measure Analyze Improve Control (DMAIC) phases. The QA team analyzed the previous state of sample shipments and then suggested improvements based on an optimized process. The results showed a set of non-value added activities specifically in transportation, motion, waiting, defects, and the sub-utilization of people. Based on Lean tools, the improvements achieved a 26 % reduction in the cycle time spent and no complaints from customers have been reported since implementation of the new process. In addition, a control plan was also developed to track shipments and maintain open and close communication with the customer. Finally, the resulting processes that have been implementation have a significant impact on reducing distribution costs.