Six Sigma in a low volume and complex environment

Purpose – The purpose of this paper is to understand how the full potential of the global phenomenon “Six Sigma” can be realised in low volume, high complex manufacturing. Design/methodology/approach – The research reported on in this paper is based on a case study company – ComplexCo plc. A questionnaire to gauge user perceptions about the tools and techniques was used, combined with interviews with five master black belts (MBB) which were conducted as part of the study. The usefulness and the frequency of use of common Six Sigma tools and techniques as deployed in low volume complex manufacturing was gauged and also the identification of the key challenges faced during Six Sigma deployment in ComplexCo are explored. Findings – The analysis clearly shows that the difficulty in acquiring data is restricting the use of analytically biased tools during the analyse phase of DMAIC (Define Measure Analyse Improve Control). It was also evident, through all stages of DMAIC, that the “softer” tools are deployed more often and the usefulness rank higher than for the “harder” tools. Finally an alternative to the traditional DPMO metric was developed called “% Right First Time”. Research limitations/implications – The paper is based on a single case study company and so the results from the study are not currently widely generalisable. Originality/value – There is a lack of literature available which explores the deployment of Six Sigma in low volume, high complex manufacturing environments. This paper contributes to the body of knowledge through the establishment of adaptations, which both ComplexCo and other organisations can use to successfully deploy Six Sigma programmes in low volume and high complex manufacturing.