A study on critical failure factors of Design for Six Sigma in Indian companies: results from a pilot survey

Abstract

PurposeWhile Six Sigma (SS) has been deployed effectively in Indian manufacturing and service sectors as a process improvement methodology, the implementation of Design for Six Sigma (DFSS) for robust product and service development has not shown noticeable results. Therefore, this article aims to determine the critical failure factors (CFFs) of DFSS in the Indian context.Design/methodology/approachThe paper presents the results of a pilot survey on the CFFs of DFSS in Indian companies. The survey participants were specialists in DFSS who have been involved in DFSS projects in their past and present companies. Moreover, the pilot study participants were DFSS Champions, Master Black Belts, Black Belts and Green Belts from the manufacturing and service sectors.FindingsCompany-wide applications of DFSS are very limited in India. Most of the DFSS project failures are reported in the Analyse phase of the project. The results indicated that all 18 CFFs used in the survey have a significant impact on project failures. Also, it was determined that all CFFs are positively correlated with each other. Further, a strong correlation was observed between the voice of the customer (VOC) and project selection and prioritisation. In addition, effective training showed a strong correlation with the right selection of tools.Research limitations/implicationsThe pilot survey was based on a limited sample size. Moreover, the study is confined to only the Indian context and data were collected through the authors' networks. However, respondents were proficient, certified and involved in DFSS project deployment in the manufacturing and service sectors. Therefore, the study's findings are useful and meaningful to draw robust inferences.Originality/valueTo the best of the authors' knowledge, this is the first empirical study conducted in the Indian context to identify the reasons for DFSS project failures. The study's findings can aid academicians and practitioners in comprehending and critically examining the CFFs of DFSS before executing a project. Moreover, the research outcome motivates policymakers to create an ecosystem to effectively adopt DFSS for start-ups and micro, small and medium enterprises (MSME) to ensure a circular economy and support the “Atmanirbhar Bharat” initiative.

How The TQM Journal has addressed “quality”: a literature review using bibliometric analysis

“…Bhat and Rajashekhar (2009) identified the barriers of TQM implementation in the Indian business context. Later, Bhat et al . (2022a, b) demonstrated that the application of DFSS for reliable product and service development had not yielded appreciable results.…”

“…Cluster 3 represents the keywords critical success factor, six sigma, healthcare, process engineering, decision support systems, lean production and quality (Lande et al ., 2016; Bouranta et al ., 2017; Cho et al ., 2011; Clegg et al ., 2010; Maleyeff et al ., 2012; Antony et al ., 2019, 2022; Antony et al ., 2022a, b; Bhat et al ., 2022a, b). Accordingly, the cluster is themed as “Quality Measurement Tools and Models”.…”

“…The articles in this cluster broadly discuss how to measure quality through quality management techniques, such as lean, six sigma and lean six sigma to provide a sustainable product (Lande et al ., 2016; Bouranta et al ., 2017; Cho et al ., 2011). These articles also discuss the various techniques of “Quality improvement” which can support intelligent decision-making and ensure high quality in products and services (Lande et al ., 2016; Bouranta et al ., 2017; Cho et al ., 2011; Clegg et al ., 2010; Maleyeff et al ., 2012; Antony et al ., 2019, 2022; Bhat et al ., 2022a, b) by leveraging tools such as such as Cause and Effect diagram, Control Charts, Histogram, Pareto Charts and Flow Chart. The cluster also critiques the critical success factors for dimensions such as education, manufacturing and healthcare.…”

“…Design for Six Sigma (DFSS) implementation, quality measurement and impediments are the main topics of cluster 4 (Bhat et al ., 2020, 2022a, b; Gijo et al ., 2021). Bhat and Rajashekhar (2009) identified the barriers of TQM implementation in the Indian business context.…”

Analyzing critical factors of strategic alignment between operational excellence and Industry 4.0 technologies in smart manufacturing

“…Therefore, the integration of OPEX methodologies in manufacturing industries with I4.0 technologies and other digital applications provides benefits such as increasing total equipment efficiency, maximizing value-added activities (Tissir et al, 2022), eliminating waste, increasing efficiency, reducing costs, producing quality products according to customer demand and increasing customer satisfaction accordingly (Trakulsunti et al, 2022). This means that important factors need to be addressed to establish strategic alignment between OPEX methodologies and I4.0 technologies in manufacturing sectors (Bhat et al, 2022). These factors enable the establishment of strategic alignment between OPEX methodologies and I4.0.…”