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"Powell, Daryl"
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The evolution and future of lean Six Sigma 4.0
PurposeThis purpose of this study is to provide an overview of the current state of research on Lean Six Sigma (LSS) and Industry 4.0 and the key aspects of the relationships between them. The research analyses LSS's evolution and discusses the future role of LSS 4.0 in an increasingly digitalized world. We present the benefits and motivations of integrating LSS and Industry 4.0 as well as the critical success factors and challenges within this emerging area of research.Design/methodology/approachA systematic literature review methodology was established to identify, select and evaluate published research.FindingsThere is a synergistic nature between LSS and Industry 4.0. Companies having a strong LSS culture can ease the transition to Industry 4.0 while Industry 4.0 technologies can provide superior performance for companies who are using LSS methodology.Research limitations/implicationsOne limitation of this research was that as this area is a nascent area, the researchers were limited in their literature review and research. A more comprehensive longitudinal study would yield more data. There is an opportunity for further study and analysis.Practical implicationsThis study reviews the evolution of LSS and its integration with Industry 4.0. Organisations can use this study to understand the benefits and motivating factors for integrating LSS and Industry 4.0, the Critical Success Factors and challenges to such integration.Originality/valueThis is the first systematic literature review on LSS 4.0 and can provide insight for practitioners, organisations and future research directions.
Journal Article
Lean and action learning: towards an integrated theory?
PurposeBeing acquainted with both lean and action learning in theory and in practice, this study finds that the theoretical complementarity of these two research streams has traditionally been underexploited. In this conceptual paper, this study aims to advance the theoretical understanding of lean by exploring the complementarity of lean thinking and action learning leading to a proposed integrated theory of these two research streams. Target audience is the operations management research community.Design/methodology/approachBy deliberately adopting a process of theorising, this paper explores, reflects upon and combines individual experiences of researching, teaching and engaging in lean and action learning as operations management scholars.FindingsHaving taken a gemba walk through the literature and practices of lean and action learning, this study views and notices a systematic and complementary relationship between the two domains. The overlapping theoretical and practical complementarities of lean and action learning suggest that these two research streams are ripe for synthesis into an integrated theory. This finding provides an opportunity to (1) progress towards an integrative design of interventions leading to more sustainable lean system adoptions and (2) add new depth to our theoretical explanation of the success and failures of lean system adoptions.Originality/valueThis paper contributes an original integrated theory perspective on lean and action learning.
Journal Article
Lean Six Sigma and environmental sustainability: the case of a Norwegian dairy producer
Purpose
The purpose of this paper is to investigate the application of Lean Six Sigma (LSS) in the continuous process industry, taking an insight into the food processing industry; and to evaluate the impact of LSS on environmental sustainability. The authors present observations and experiences from the application of LSS at a Norwegian dairy producer, with the aim of bringing out pertinent factors and useful insights that help us to understand how LSS can contribute toward greater environmental sustainability in this industry type, something that is so far lacking in the extant literature.
Design/methodology/approach
The authors adopt a single, longitudinal field study approach as we observe an entire cycle of the VSM-DMAIC (value stream mapping-define, measure, analyze, improve and control) LSS process, which evolved over a six-month period at the dairy.
Findings
The authors highlight some of the important elements that should be considered when using LSS as a contributor toward greater environmental sustainability in fresh-food supply chains. The authors also present some of the specific outcomes and key success criteria that became apparent to the implementation team following the deployment of the VSM-DMAIC approach.
Originality/value
The authors demonstrate how LSS can be applied in the food processing industry as a contributor to greater environmental sustainability. The authors also make useful reflections regarding the success criteria that can be used by researchers and practitioners for the effective deployment of such an approach, particularly in the continuous process industry.
Journal Article
Digitalization in lean manufacturing firms: a cumulative capability development perspective
PurposeThe purpose of this paper is to examine the digitalization of operational processes and activities in lean manufacturing firms and explore the associated learning implications through the lens of cumulative capability theory.Design/methodology/approachAdopting a multiple-case design, we examine four cases of digitalization initiatives within lean manufacturing firms. We collected data through semi-structured interviews and direct observations during site visits.FindingsThe study uncovers the development of learning capabilities as a result of integrating lean and digitalization. We find that digitalization in lean manufacturing firms contributes to the development of both routinized and evolutionary learning capabilities in a cumulative fashion.Originality/valueThe study adds nuance to the limited theoretical understanding of the integration of lean and digitalization by showing how it cumulatively develops the learning capabilities of lean manufacturing firms. As such, the study supports the robustness of cumulative capability theory. We further contribute to research by offering empirical support for the cumulative nature of learning.
Journal Article
Improving value chain data lifecycle management utilising design for Lean Six Sigma methods
PurposeThis project aims to optimise a secondary agricultural company’s reporting and data lifecycle by providing self-help business intelligence at an optimal price point for all business users.Design/methodology/approachA design for Lean Six Sigma approach utilising the define, measure analyse, design and verify methodology was utilised to design a new reporting and data product lifecycle.FindingsThe study found that this approach allowed a very structured delivery of a complex program. The various tools used assisted greatly in delivering results while balancing the needs of the team.Practical implicationsThis study demonstrates how improving data analysis and enhanced intelligence reporting in agribusinesses enable better decision making and thus improves efficiencies so that the agribusiness can leverage the learnings.Social implicationsImproving data analysis increases efficiency and reduces agrifood food wastage thus improving sustainability and environmental impacts.Originality/valueThis paper proposes creating a standardised approach to deploying Six Sigma methodology to correct both the data provisioning lifecycle and the subsequent business intelligence reporting lifecycle. It is the first study to look at process optimisation across the agricultural industry’s entire data and business intelligence lifecycle.
Journal Article
Exploring the archetypes of engineer-to-order: an empirical analysis
Purpose
– The purpose of this paper is to conceptualize archetypes of engineer-to-order (ETO) to support companies in determining the appropriate degree of design standardization and automation, and as a result achieve superior performance. Products of ETO manufacturers are classified in a 2×2 matrix using annual units sold and engineering complexity as dimensions.
Design/methodology/approach
– This research adopted a theory refining approach based on multiple case studies. Seven ETO manufacturers from different industry sectors participated in the study. Data collection was primarily based on a series of in-depth interviews supported by observations and archival sources.
Findings
– The paper proposes four distinct archetypes of ETO (complex, basic, repeatable, and non-competitive) and empirically validates three of them. The organizational structures and processes most suitable for the different archetypes are described, and standardization and automation strategies are linked to the quadrants of the matrix. The matrix can support practitioners in making strategic choices and provides a framework for benchmarking their ETO products and processes.
Originality/value
– Existing conceptualizations of ETO consider the company as the primary object of investigation, rather than the product or product family. However, companies often have different product families demanding different strategies. Also, there is little or no focus on the engineering perspective. The authors move the engineering perspective to the center of investigation and identify a set of standardization and automation strategies for different types of ETO products.
Journal Article
Digital culture, knowledge, and commitment to digital transformation and its impact on the competitiveness of Portuguese organizations
This study aimed to understand the impact of digital culture on companies' knowledge and constant commitment to digital transformation, as well as its impact on organizations as a whole. Secondly, it aimed to explore the impact of digital technology adoption on organizational performance and competitiveness. Finally, the study investigated the role of knowledge management during digital transformation. A quantitative study was developed using a descriptive design. A questionnaire was developed on pre-test was carried out withon 15 participants and since no doubts or difficulties were detected, it was made available on the internet between January and April 2022. A total of 291 questionnaires were collected and validated. Data were imported from Google Forms for analysis in SPSS, version 25.0, andSmartPLS® 4.0 software. The questionnaire revealed good internal consistency (» = 0.922). Ten of the twelve hypotheses were confirmed, that is, the existence of positive and significant relationships between digital culture (DC) and knowledge of digital transformation (KDT); DC and adoption of digital technologies (ADT); DC and knowledge management (KM); commitment (C) and KDT; C and productivity (P); KDT and ADT; ADT and KM; ADT and P; ADT and C; and P and C. The results of regression analyses showed that the variables that contributed to the model (\"competitiveness of organizations\") were productivity, the adoption of digital technologies, commitment to digital technologies, and knowledge management. The variables CD and KDT (Knowledge of digital transformation) presented lower and non-significant values.
Journal Article
Decision Making in Service Shops Supported by Mining Enterprise Resource Planning Data
This research examines the application of Enterprise Resource Planning (ERP) systems in service shops, focusing on the specific challenges unique to these environments compared to those in the manufacturing sector. Service shops, distinguished by their smaller scale and variable demands, often need different functionalities in ERP systems compared to manufacturing facilities. Our analysis is based on detailed billing records and monthly cash flow data to deliver critical insights into businesses’ performance for service shop managers. This study analyses ERP data from 27 service shops over 35 months. It is based on detailed billing records and monthly cash flow data to deliver critical insights into businesses’ performance for service shop managers that support managerial decision making. Our findings emphasise the importance of incorporating additional contextual information to augment the effectiveness of ERP systems in service contexts. Our analysis shows that simple, standardised data mining methods can significantly enhance operational management decision making when supported with visuals to support understanding and interpretation of the data. Moreover, this study suggests potential directions for future research aimed at improving business analytics and intelligence practices to optimise the use of ERP systems in service industries. This research contributes to the academic discourse by providing empirical evidence on utilising ERP data in service shops and offers practical recommendations for ongoing operational improvements.
Journal Article
Rethinking lean supplier development as a learning system
PurposeThis paper investigates developing a learning-to-learn capability as a critical success factor for sustainable lean transformation.Design/methodology/approachThis research design is guided by our research question: how can suppliers learn to learn as part of a buyer-led collaborative lean transformation? The authors adopt action learning research to generate actionable knowledge from a lean supplier development initiative over a three-year period.FindingsDrawing on emergent insights from the initiative, the authors find that developing a learning-to-learn capability is a core and critical success factor for lean transformation. The authors also find that network action learning has a significant enabling role in buyer-led collaborative lean transformations.Originality/valueThe authors contribute to lean theory and practice by making the distinction between learning about and implementing lean best practices and adopting a learning-to-learn perspective to build organisational capabilities, consistent with lean thinking and practice. Further, the authors contribute to methodology, adopting action learning research to explore learning-to-learn as a critical success factor for sustainable lean transformation.
Journal Article