Implementing a Lean Six Sigma standardized toolset in a manufacturing company: a case study

Abstract

Purpose

The first purpose of this paper is the implementation of Lean Six Sigma (LSS) in a manufacturing company operating in South East Europe in order to understand the importance of critical success factors (CSFs) in LSS adoption and to find out the benefits that the company gained. The second purpose is to propose a standardized toolset based on DMAIC phases, for the application of LSS in small scale projects, in order to facilitate LSS adoption by more manufacturing companies.

Design/methodology/approach

This case study is based on the interlacement of the Yin's method about case studies and the DMAIC method for the improved deployment of LSS.

Findings

The analysis of this case study shows that the company attained to benefit financially, operationally and organizationally from the implementation of LSS. The already existing mentality of CI inside the company helped the project procedure and the application of changes and improvements fulfilling LSS adoption CSFs.

Practical implications

The paper constructs a toolset and studies the role of CSFs in order to achieve the desirable benefits in a manufacturing environment, constituting a guide for future LSS initiatives.

Originality/value

As stated by literature reviews, even though there are several papers concerning LSS implementation in the manufacturing sector, there is a need for more case studies papers, such as this one, in order to enrich the literature. In this paper, it is also the first time that a specific toolset for small scale projects is proposed based on to DMAIC which can be implemented in further LSS projects.

Citation

Panayiotou, N.A., Stergiou, K.E. and Chronopoulos, V. (2022), "Implementing a Lean Six Sigma standardized toolset in a manufacturing company: a case study", International Journal of Productivity and Performance Management, Vol. 71 No. 4, pp. 1164-1187. https://doi.org/10.1108/IJPPM-08-2020-0423