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Sustainable
QUALITY PAPER implementation
Scoping review of the readiness for of LSS projects
sustainable implementation of
Lean Six Sigma projects in the 1747
manufacturing sector Received 6 August 2020
Revised 27 November 2020
21 December 2020
Alireza Shokri Accepted 23 December 2020
Faculty of Business and Law, Northumbria University, Newcastle upon Tyne, UK
Jiju Antony
Edinburgh Business School, Heriot-Watt University, Edinburgh, UK
Jose Arturo Garza-Reyes
Derby Management School, The University of Derby, Derby, UK, and
Michelle Upton
The York Management School, University of York, York, UK
Abstract
Purpose – This work presents a synthesis of current literature published from 2010 to provide an overall
understanding of the sustainable implementation of Lean Six Sigma (LSS) projects in terms of project
approaches rather than outcomes.
Design/methodology/approach – A comprehensive and validated ten-step model was applied to conduct a
scoping review with the following three broad phases: “review planning”, “review execution” and “review
reporting”.
Findings – The analysis shows that while a few geographically and methodologically broad research studies
have been conducted on LSS and green manufacturing integration, no studies have examined organisational
culture or conducted readiness assessments on the sustainable implementation of LSS projects in the
manufacturing sector.
Research limitations/implications – The present study contributes to existing knowledge by describing
the current state of research on green LSS integration. The study also identifies a lack of research on the
deployment of sustainable LSS projects for manufacturers. Further empirical analyses that include case studies
must be conducted to assess the negative environmental impacts of LSS projects.
Originality/value – This study serves as an initial call for practitioners and research scholars to favour the
sustainable deployment of LSS projects in manufacturing alongside the use of traditional approaches with a
focus on costs, quality and delivery.
Keywords Lean Six Sigma, Green manufacturing, Organisational culture, Scoping review, Systematic
literature review
Paper type Literature review
1. Introduction
Evaluating sustainability non-financial key performance indicators and subsequently
mitigating the detrimental impacts of the failure of management systems on the
environmental sustainability are crucial and deserve further exploration (Karevan et al.,
2020; Dissanayake, 2020). Due to changing public perceptions and market dynamics and
increased public and regulatory pressures, a stakeholder-oriented integration of International Journal of Quality &
Reliability Management
Vol. 38 No. 8, 2021
pp. 1747-1770
This scoping review was carried out as part of our funded British Academy Small Grant project (Ref. © Emerald Publishing Limited
0265-671X
SRG180254). DOI 10.1108/IJQRM-08-2020-0261
IJQRM environmental sustainability and energy efficiency into continuous improvement (CI)
38,8 methodologies such as Lean Six Sigma (LSS) is becoming a necessity in manufacturing
(Jayaraman et al., 2012; Erdil et al., 2018; Mishra, 2019; De Freitas et al., 2017; Kaswan, 2019).
Furthermore, according to Lucato et al. (2015) and Ghazilla et al. (2015), a growing number of
manufacturing firms running LSS projects are more susceptible to adverse environmental
impacts of LSS project deployment and resources while gaining economic competitiveness.
The manufacturing industry is also facing more pressures to adhere to stringent
1748 environmental regulations and more resource-efficient operations.
Very few studies have been conducted on the importance of the synergic integration of the
contemporary LSS framework with environmental sustainability frameworks for the
manufacturing sector (De Freitas et al., 2017; Mishra, 2019). Examples of such studies include
Ruben et al. (2018), Cherrafi et al. (2016) and Cherrafi et al. (2017), but they are overwhelmingly
conceptual and bibliographically incipient. Moreover, an absence of a sustainability
framework for LSS project deployment leaves energy efficiency plans among manufacturing
firms that implement LSS more likely to fail (Antony et al., 2017). Despite proven outcome
benefits such as lower waste and operation costs and market opportunities, the integration of
environmental sustainability with LSS in the manufacturing sector remains highly complex
due to a profound focus on economic and quality–centred objectives of LSS (De Freitas et al.,
2017; Erdil et al., 2018). This strong prioritisation conflicts with other manufacturing
principles such as green credentials.
Additionally, the importance of sustainable LSS projects was highlighted by scholars (Brkic
and Tomic, 2016). Therefore, this study aims to take the first step and scope and synthesise the
current literature to check whether there is a gap in the literature about assessing readiness of
sustainable utilisation and deployment of LSS projects. The literature synthesis focuses on
green LSS project deployment and critical success factors (CSFs), drivers and barriers.
Therefore, we describe the current literature associated with the definition of LSS, green LSS
and organisational culture, critical factors affecting LSS, green LSS failure and success and
drivers and barriers of LSS and green LSS as search keywords of this scoping review.
2. LSS definition
LSS is a newer form of the linear combination of lean and Six Sigma. LSS is a strategic, rigid and
structured improvement procedure with operational capabilities and approaches for reducing
variation in organisational processes (Zu et al., 2010; Manville et al., 2012; Antony et al., 2017).
LSS is today’s leading technique for maximising production efficiency and maintaining control
over each step of the managerial process (George et al., 2005). Alexander et al. (2019), Laureani
and Antony (2018) and Albliwi et al. (2015) recently defined LSS as a powerful method when
combined with process improvement and shareholder value maximisation approaches with
ultimate objectives of increased efficiency, customer satisfaction, reliability and process
performance optimisation. Highly structured breakthrough projects have rendered LSS a
stable management process and guided form of resource allocation that focuses on the
organisational bottom line. LSS has in turn become a popular quality and business
improvement methodology pivotal to business excellence and competitive advantage (Ismyrlis
and Moschidis, 2013; Sreedharan et al., 2019; Sharma and Sharma, 2014; Antony, 2006).
4. Factors shaping the success and failure of LSS and green LSS
The integration of LSS with sustainability frameworks to reduce environmental impact
seems to be an essential factor that shapes future success or failure. Through a high-level
overview, Snee (2010) highlighted the role of top leaders in creating a sense of urgency to
support more productive LSS project selection and sustainability, aligning with the start of
LSS integration with green manufacturing in 2010 (De Freitas and Costa, 2017). Ruben et al.
(2018) highlighted that any contemporary LSS framework must consider elements of eco-
efficiency, according to which environmental impacts of LSS must be considered similar to
quality and cost reduction impacts on project outcomes. The green LSS model has emerged as
a way for organisations to achieve better environmental efficiency while pursuing their
economic goals (Mishra, 2019). However, considerable focus has been placed on LSS
outcomes rather than on environmental impacts of LSS projects themselves. Drohomeretski
et al. (2014) conducted a preliminary comparative analysis of decision-making criteria and
performance objectives of LSS as a means to achieve a strategic competitive advantage in the
Brazilian manufacturing sector. Kuvvetli et al. (2016) identified CSFs of Six Sigma for Turkish
manufacturers through a factor analysis. Both of these studies recommended skills and
capacity of the workforce, managerial technical competence, competence to meet clients’
expectations, workforce participation, investment in strategic development, effective
application of methodology and appropriate project selection as criteria to achieve a
strategic competitive advantage.
Through a case study analysis of the UK, Manville et al. (2012) highlighted the role of
middle management in creating a cultural platform via dynamic capabilities and culture of
organisational learning for LSS project success. More recently, Laureani and Antony (2018)
emphasised the role of transformational leadership in creating certain culture and objectives
and in adopting cultural changes through CSFs of LSS. Jayaraman et al. (2012) also identified
IJQRM the CSFs of LSS from a practitioner’s point of view and the importance of organisational
38,8 culture to LSS success. Furthermore, Naslund (2013) revisited CSFs of LSS by focusing on
strategic alignment, top management commitment, project management and training as four
crucial factors.
Top management commitment, organisational culture, relating LSS to business strategies
and leadership have been deemed the most important CSFs for LSS (Snee, 2010; Laureani and
Antony, 2012). Through their quantitative analysis of the Malaysian automotive sector,
1750 Habidin and Yusof (2013) identified effective leadership and top management commitment as
drivers of other CSFs of LSS such as customer focus. Meanwhile, Ismyrlis and Moschidis
(2013) classified CSFs of LSS in terms of hard and soft elements where soft elements are
mainly associated with leaders and people as two common enablers of any quality
improvement initiative. More recently, Sreedharan et al. (20118a) assessed critical factors
resulting in the failure of LSS methods in manufacturing through a case study analysis in
India. Their finding highlighted lack of top management commitment, high implementation
cost and internal resistance as top LSS critical failure factors to be considered in the real-
world scenario. De Freitas and Costa (2017) found that 70% of companies fail to implement
LSS as a strategy due to several factors such as a lack of top management commitment and
support, limited training, poor project prioritisation, lacking resources and the limited
integration of LSS projects and business or corporate strategies. Abu Bakar et al. (2015)
reviewed and gathered the latest success factors of LSS deployment and implementation into
a comprehensive list of factors through a literature review. Their study recommended
management commitment, LSS competency, training, organisational infrastructure and
project management as the top five critical success factors of LSS.
More recently and through empirical research, Mishra (2019) evaluated existing
frameworks of green and LSS integration in the literature and recommended top
management commitment, dedication to appropriate strategy selection, long-term planning
and participation and a strong understanding of current products and process designs as top
factors facilitating the achievement of desired level of success. However, their study focused
on the role of LSS in waste reduction as a green outcome and not on the actual deployment of
LSS projects with attention to resource and energy efficiency. Albliwi et al. (2014) explored a
comprehensive list of common factors causing LSS project failure and indicated that a
significant percentage of these factors are related to a lack of appropriate attention given to
CSFs of LSS. Hilton and Sohal (2012) stressed the importance of developing a unique
combination of personal and corporate competencies such as knowledge, skills, charisma and
organisational change management for LSS success and sustainability. Sunder (2016)
highlighted the importance of projects and “Inform-Involve-Influence” models of stakeholder
management for LSS project success. Tenera and Pinto (2014) adopted an alternative view of
LSS success by proposing an LSS project management improvement model integrated with
the LSS methodology to avoid excessive LSS project durations and resource overuse as key
operational and environmental factors resulting in failure. Antony et al. (2017) shared the
experience of LSS practitioners and academics in concluding that focusing on more holistic
organisational improvements through sustainable initiatives is essential to future LSS
implementation. Later, Hudnurkar et al. (2019) conducted a preliminary quantitative study on
deficiencies in Six Sigma project capabilities and recommended organisational capability
utilising resources as key element to minimise deficiencies to perform a coordinated set of
activities.
6. Methodology
Despite there being an accurate account of the positive impact of LSS on green
manufacturing, there is a need for holistic evidence on the sustainable implementation of
LSS projects in manufacturing and on cultural approaches to such a change. We conducted
scoping review (SR), which is a relatively new and increasingly popular approach for
synthesising research evidence (Pham et al., 2014; Munn et al., 2018). The SR is almost similar
to the systematic literature review to provide a rigorous and transparent method for mapping
areas of research and existing literature (Pham et al., 2014; Munn et al., 2018). The systematic
literature review approach involves conducting a structured review of the current literature
to advance our understanding of emerging research and to identify the conceptual content of
the field as part of a theoretical contribution (Alinaghian et al., 2020; Chugani et al., 2017).
However, a SR of a body of literature can be of particular use when the topic has not yet been
extensively reviewed to examine the extent, range and nature of research activity in a topic
area, to summarise and disseminate research findings and to identify gaps in the existing
literature (Pham et al., 2014). Therefore, this method was the most suitable literature review
approach for the purpose of our study.
A number of systematic literature review papers have been published on the impact of
LSS on green outcomes (Chugani et al., 2017), on green lean approaches and the need for Six
Sigma methods (Garza-Reyes, 2015), on LSS for manufacturing (Albliwi et al., 2015), on LSS
for manufacturing SMEs (Alexander et al., 2019) and on LSS in the food industry (Costa et al.,
2018). Nevertheless, we found no SR about the integration of LSS and green manufacturing.
Therefore, in light of the aims of this study, we conducted a SR of relevant literature by using
a comprehensive pre-planned strategy to identify a gap in the literature about readiness
assessment of sustainable implementation of LSS projects in manufacturing. The SR
approach elucidates the effects of previous research through a broad synthesis of
contributions and gaps of current research (Alexander et al., 2019; Albliwi et al., 2015). The
SR method, thus, serves as a rigorous, transparent and explicit means to ensure a
comprehensive literature review (Garza-Reyes, 2015).
We adopted the comprehensive approach recommended by Tranfiled (2003), Albliwi et al. Sustainable
(2015) and Alexander et al. (2019) in using a ten-step SR approach to examining LSS in the implementation
manufacturing industry. The three broad phases of this ten-step approach (review planning,
review execution and review reporting) are presented in Figure 1.
of LSS projects
Figure 1.
Summary of scoping
review approach and
phases
Included Excluded
Articles published in peer-reviewed academic Books, book chapters, articles published in non-peer-
journals reviewed journals, and business reports/articles
Articles related to LSS and green manufacturing Articles on other subjects and sectors
Articles published in English Articles published in languages other than English
Articles published from 2010 Articles published before 2010 Table 1.
Articles focused on cultural aspects of LSS and its Other LSS articles Scope and criteria of
integration with green manufacturing the SR
IJQRM the first stage of literature review based on our research aims and objectives: “LSS/Six Sigma
38,8 culture”, “LSS/Six Sigma and manufacturing”, “LSS/Six Sigma and sustainability” and “LSS/
Six Sigma and green manufacturing”. The search was carried out using major electronic
social science, business and management databases and publishing websites, including
Emerald, Elsevier, Green file, the Sage Premier journal collection, the Science Direct freedom
collection, Scopus, Springer link contemporary, the Taylor and Francis library and Wiley
online. The search initially identified 51,600 articles from our screening and scoping process.
1754 After applying exclusion and inclusion criteria as part of the scoping stage, 1,133 articles
were identified as potential materials for the SR.
After cross-checking through title and keyword screening and removing duplicate and
irrelevant results, 144 articles were identified as the most suitable and relevant according to
their topics and keywords and based on our third layer search keys and themes. The cross-
checking happened among three experienced researchers and academics, of which one of
them as a Professor and LSS expert (with Master Black Belt qualification), the other one an
Associate Professor and LSS expert (with Green Belt qualification) publishing many papers
about LSS in combination. The third one is a Professor and an expert in sustainability
publishing papers about green manufacturing. Each stage of screening and scoping was
verified and cross-checked by all three members of the team through sharing synthesis
documents such as excel spreadsheet of data and brainstorming.
These themes included the following: “green manufacturing and its drivers and barriers”,
“green LSS and organisational culture”, “factors shaping the critical success or failure of
green LSS” and “green LSS integration and its drivers and barriers”. These four search keys
were classified as four themes for final scanning and scoping due to their contributions to our
main search keywords (culture and readiness to adopt green LSS projects in manufacturing).
Finally, 73 articles were selected after a final screening of abstracts. Figure 2 summarises the
scoping and screening process used.
The 73 journal articles selected as relevant to the four identified themes and research
objectives are published in a variety of journals of different publishers. We have identified
that some articles shared search keys as part of our second round of cross-checking. Most are
published in mainstream LSS journals such as the “International Journal of LSS” and
Figure 2.
Article selection and
screening process
“International Journal of Quality and Reliability Management”. Many of the articles focused Sustainable
on green and LSS integration are published in the “Journal of Cleaner Production”. Figure 3 implementation
shows the number of papers published in each journal.
Figure 4 shows a distinct positive trend of interest in research and publication on green
of LSS projects
and LSS integration and its cultural aspects in general, clearly showing that the integration of
environmental sustainability with LSS and cultural receptiveness to the idea has recently
become a prominent area of research. Statistics for 2019 are incomplete, as data were
extracted in mid-2019. 1755
Figure 3.
Number of papers
published in each
journal
CHART TITLE
16
14
12
10
8
6 Figure 4.
4
Number of papers
published each year
2
across the period
0
studied
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019
IJQRM
38,8
1756
Figure 5.
Most frequently used
keywords
in these articles are widely used in many LSS articles with environmental sustainability being
the only sustainability-focused keyword of the most frequently used keywords. Words such
as “drivers”, “barriers” and “energy efficiency” are used less frequently. “Green LSS” also
appears among the least widely used of more common keywords. In addition, “sustainable
implementation of LSS”, “green LSS project” and “energy efficient LSS project” are not
identified as major keywords.
6.3.2 Research method applied. Our analysis of research methods used in the sampled
studies reveals the most and least frequently used methods for examining the integration of
LSS and green manufacturing and its cultural aspects. The analysis reflects approaches
widely used in studies of this field, revealing more popular research methods. Survey
questionnaires and case studies are the most common followed by systematic literature
reviews (Figure 6). The large share of systematic literature reviews found demonstrates the
popularity of this method among scholars of this area and opportunities to identify current
gaps in the literature and avenues for further research. However, no SR was found among
methodologies in this field.
6.3.3 Distribution of research publications across different countries. Our geographic
analysis of research studies and their publication specifications reflects research interest in
UAE
Taiwan
Sweden
Spain
Singapore
Serbia
Romania
Portugal
Palestine
Norway
Netherland
Morrocco
Jordan
Italy
Hong Kong
Greece
Global
Germany
Denmark
Turkey
Egypt
Australia
China
USA Figure 7.
Malaysia Distribution of
Brazil research and
UK
India publication across
countries
0 5 10 15 20
IJQRM organisational culture and its features for LSS among the studied articles and across different
38,8 countries, analyses of organisational cultures for green LSS integration appear to be less
common across the research publications. Table 2 presents a summary of this analysis.
6.3.4.2 Factors affecting the success or failure of LSS and green LSS. Our careful analysis
of 20 articles covering a broad geographic distribution among developing and developed
countries reveals a focus of research on the success of LSS projects in the manufacturing
sector. Approaches used in this research are both broad in examining many different factors
1758 and narrow in assessing a few selected factors such as leadership, top and middle level
management commitment, project management, stakeholder analysis and training. Most of
the articles only focus on LSS projects and only three evaluate factors affecting the success or
failure of green LSS integration. As shown in Table 3, a systematic literature review by Ruben
et al. (2018) proposes an integrated framework of green LSS implementation. Through a
detailed case study analysis, Mishra (2019) identified CSFs of green LSS integration. Both of
these studies conducted in India examine green LSS integration outcomes (i.e. waste
reduction) rather than LSS project deployment (i.e. energy and resource efficiency across the
project life cycle).
6.3.4.3 Drivers of and barriers to LSS and green LSS. The final step of our focused analysis
on the 28 selected articles reveals the importance of analysing drivers of and barriers to LSS
and its integration with other management concepts such as environmental sustainability.
Studies on this element of cultural assessment are also geographically broad, as scholars
from both developed and developing countries are interested in exploring drivers and
barriers as important indicators of cultural evaluation. However, some of the studies focus on
drivers of and barriers to LSS or on more general cultural aspects such as LSS project
deficiencies. In contrast, some articles focus on drivers of and barriers to green LSS
integration. Erdil et al. (2018), Cherrafi et al. (2016), De Freitas et al. (2017) and De Freitas et al.
(2017) adopt more general approaches to green LSS integration by using a three-dimensional
definition of sustainability that covers environmental sustainability. Sagnak and Kazancoglu
(2016), Garza Reyes (2015), Lucato et al. (2015) and Mkhaimer et al. (2017) mainly focus on
incorporating environmental variables and energy management into LSS processes.
Studies by Kumar et al. (2016), Garza-Reyes et al. (2018) and Kaswan (2019) focus on
barriers to and drivers of LSS integration with green production. Cherrafi et al. (2017) and
Powell et al. (2017) adopt an alternative approach by evaluating how LSS can reduce
environmental impacts of final products. Banawi and Bilec (2014) and Aldairy et al. (2017)
propose environmental integration with LSS in the construction industry. None of these
studies however evaluate or analyse drivers of and barriers to the green deployment of LSS
projects in the manufacturing sector. A summary of these articles is presented in Table 4.
(continued ) Table 3.
IJQRM Theme Author Country Focuses Limitations
38,8
Laureani and The UK Identifies and ranks CSFs of A survey study focused on
Antony (2012) LSS presented in the CSFs of LSS without
literature and in reference to green
preliminary research paradigms
Albliwi et al. The UK Explores factors affecting A study focused on factors
1762 (2014) LSS failure in different affecting LSS failure
sectors through a without reference to green
systematic literature review paradigms
Snee (2010) The USA Provides a high-level Presents a high-level
overview on Six Sigma, overview of LSS with
Lean and LSS methods for reference to generic LSS
the past few years CSFs and without
reference to green
Table 3. paradigms
Table 4. (continued )
Theme Author Country Focuses Limitations
Sustainable
implementation
Sagnak and Turkey Presents action-based An action-based study of LSS projects
Kazanancoglu research on the integration examining the role of Six
(2016) of lean, Six Sigma and green Sigma in mitigating
manufacturing to mitigate limitations of green and
limitations of green and lean lean integration with no
integration and to assess the reference to the cultural 1765
role of this integration in assessment of impacts of
reducing environmental LSS projects on the
impact environment
Aboelmaged The UAE Validates how the strongest A survey study of a
(2011) barriers to Six Sigma developing country
implementation may vary evaluating the role of
with dimensions of organisational factors in
organisational factors in a Six Sigma success with no
developing country through reference to green and lean
a cross-sectoral survey paradigms
questionnaire
Antony et al. The UK Reports academic and A high-level overview of
(2017) industry practitioners’ projected trends of LSS
views on LSS trends with no particular focus on
cultural assessments of LSS
and green manufacturing
integration
Albliwi et al. The UK Explores the most common Focuses only on LSS
(2015) themes of LSS in the implementation in
manufacturing sector and manufacturing with no
finds gaps in the literature reference to green
through a systematic paradigms
literature review
Garza-Reyes The UK Examines effects of Six A survey study focused on
(2015) Sigma on green and lean the capacity for Six Sigma
integration and their methods to mitigate
compatibility through a limitations of lean and
systematic literature review green integration but with
no reference to the cultural
assessment of this
integration based on project
deployment
Aldairy et al. The UK Develops a knowledge- Focuses on LSS and green
(2017) based system for LSS construction integration
maintenance in based on outcomes and not
environmentally sustainable focused on the
buildings manufacturing sector
Chugani et al. The UK Identifies environmental Focuses on LSS and green
(2017) impacts of Lean, Six Sigma integration in relation to
and LSS projects in terms of outcomes with no particular
energy use, resource assessment of cultural
optimisation and resource attributes
saving through a systematic
literature review
(continued ) Table 4.
IJQRM Theme Author Country Focuses Limitations
38,8
Alexander et al. The UK Explores the most common Presents a general yet
(2019) themes of LSS in relation to focused approach to LSS
manufacturing SMEs and implementation in SMEs
identifies research gaps with no reference to green
through a systematic paradigms
1766 literature review
Erdil et al. (2018) The USA Embeds sustainability into Develops a generic
LSS projects and practices sustainability model of
integration with LSS based
on outcome and without
reference to green
paradigms based on
deployment
Banawi and Bilec The USA Develops a systematic and A case study examining
(2014) integrated LSS and green only on the construction
framework to lessen sector based on outcomes of
environmental impacts of green LSS integration
Table 4. the construction industry
However, due to gaps in research and practice regarding approaches to green implementation
of LSS projects, we also anticipate difficulties with cultural change. Therefore, assessing
readiness for consideration of green implementation of LSS projects needs to be the first stage
gate for both scholars and practitioners. We, thus, conducted a SR of literature on the cultural
and readiness assessment of the sustainable implementation of LSS. It is crucial for managers
and scholars to assess organisational readiness for, drivers of and barriers to green LSS
implementation, which may lead to drastic cultural shifts or minimal organisational cultural
change depending on modes of LSS adoption within manufacturing firms.
Despite providing a valuable account of current research in this field, this study presents
limitations. It first focuses exclusively on academic sources from selected databases based on
a rigorous selection procedure, which may have resulted in us leaving out resources from
other sources. We also view this work as the start of a more critical investigation of the
negative impacts of failure in LSS projects. We, thus, recommend that further empirical
studies such as survey questionnaires, interview- and action-based research and case studies
to provide a clearer understanding of cultural readiness for and managerial implications of
the sustainable implementation of LSS projects. Finally, future studies can also explore the
development of a self-assessment model for evaluating the readiness of organisations to
adopt Green LSS for both manufacturing and service sector.
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Further reading
Chuang, S. and Yang, C. (2014), “Key success factors when implementing a green-manufacturing
system”, Production Planning and Control, Vol. 25 No. 11, pp. 923-937.
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Suresh, S., Antony, J., Kumar, M. and Douglas, A. (2012), “Six Sigma and leadership: some
observations and agenda for future research”, The TQM Journal, Vol. 24 No. 3, pp. 231-247.
Corresponding author
Alireza Shokri can be contacted at: alireza.shokri@northumbria.ac.uk
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