In pursuit of implementation patterns: the context of Lean and Six Sigma

TLDR

Lean and Six Sigma integration has become popular, yet it remains unclear whether the combined approach yields performance benefits beyond isolated implementation. The study aims to uncover associative and predictive patterns of Lean and Six Sigma implementation across 15 Lean practices. It analyzes implementation and performance data from 2,511 plants. The analysis shows that adopting any Lean practice raises the likelihood of Six Sigma implementation, that quality‑management bundles predict extensive Six Sigma use, and that Six Sigma implementers outperform non‑implementers. Keywords: Lean practices, Six Sigma, Lean‑Six Sigma, empirical methods.

Abstract

Abstract Combining Lean practices with Six Sigma has gained immense popularity in recent years. Whether a combined Lean-Six Sigma approach is the latest management fad, or leads to significant performance benefits that exceed isolated implementation is not yet apparent. Using implementation and performance data from a sample of 2511 plants, the research study attempts to uncover associative and predictive pattern of implementation between 15 Lean practices and the Six Sigma program. Our results indicate two major findings. First, implementation of any practice from a broader set of Lean practices improves the likelihood of implementing Six Sigma. Additionally, practices commonly bundled under quality management predict and distinguish the group of plants implementing Six Sigma extensively from non-implementers. Second, the regression results indicate a significant difference in the performance levels of the Six Sigma implementers group compared with the non-implementer group. These preliminary results are a first step towards separating fact from fiction. Keywords: Lean practicesSix SigmaLean-Six SigmaEmpirical methods