Lean Six Sigma in manufacturing SMEs : exploring the factors that affect the balance between Lean and Six Sigma

Abstract

Lean Six Sigma (LSS) is an methodology that integrates both Lean and Six Sigma principles to improve efficiency, reduce waste and enhance quality in various industries. LSS is also used within Small and Medium Enterprises (SMEs) that account for more than 99% of all companies. Although SMEs are important to the economy, they are not just smaller versions of larger organisations. It is observed that the adoption and use of LSS remains low across the manufacturing SMEs. The gap in knowledge is that, from an SME perspective the factors around the adoption and use of the integrated concept of LSS is not widely understood. Following critical and systematic literature reviews, the aim of this research was formulated to better understand the factor conditions that drive the adoption and success of LSS within manufacturing SMEs. An important concept which underpins this research is the LSS barycentre concept, which was borrowed from astrophysics which is described as the relative balance between Lean and Six Sigma. Empirical research was performed to obtain data from manufacturing SMEs in two phases with first phase comprising a survey and second phase comprising five in depth case studies. The research was performed through a Critical Realism lens, using an abductive strategy and a qualitative method. The findings of this research provide five contributions. First, a deeper understanding of the factors effecting the barycentre between lean and six sigma. Second, an insight into the LSS tools SMEs use and how these could be better bundled together for facilitate different stages of their journey. Third, a better understanding of the factors that shape LSS infrastructure necessary to support SMEs. Forth, a model (ACES), integrating strengths of previous models with the findings of this research, for facilitating implementation of LSS in SMEs. Fifth, challenging the appropriateness of monetary targets for delineating between Yellow, Green and Black belt LSS qualifications as well as the appropriateness of the exiting LSS maturity models in the context of SMEs.