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Abstract
Purpose – Process improvement initiatives, such as Lean, Six Sigma and Lean Six Sigma, typically have
common characteristics that are carried through projects. Whilst a project’s performance is an important
determinant of the successful implementation of continuous improvement (CI) initiatives, its failure can
undermine the impact of any CI initiative on business performance. As a result, an understanding of the
reasons of process improvement project failures is crucial. The purpose of this paper is to present the results
of a pilot survey highlighting the most common reasons for process improvement project failures.
Design/methodology/approach – This paper presents a pilot survey of 42 Brazilian manufacturing
specialists who have been involved in process improvement projects. The participants of this survey were Six
Sigma Master Black Belts, Black Belts, Green Belts and Six Sigma champions from manufacturing companies
in Brazil. The survey questionnaire was piloted with five experts in the field in order to ensure that the
questions were valid and technically sound.
Findings – The execution of Six Sigma projects in organizations results in a moderate rate of project failures.
These failures can cost organizations several millions of dollars especially within the context of larger
organizations. The main reasons for project failure, as cited by the specialists include: resistance to change,
lack of commitment and support from top management and incompetent teams.
Research limitations/implications – The authors report the findings from a pilot survey having a limited
sample size. Moreover, the data have been collected from one country and primarily from large
manufacturing companies.
Originality/value – To the best of the authors’ knowledge, this is the first empirical study looking into the
reasons for process improvement project failures. The authors argue that if the top reasons for such failures are
understood, a framework can be developed in the future that can mitigate the chance of project failures during
project execution. This could potentially lead to significant savings to the bottom-line of many organizations.
Keywords Process improvement, Survey, Project management, Continuous improvement projects,
Project failures, Six Sigma project failures
Paper type Research paper
1. Introduction
The need for business process improvement (BPI) has become indispensable to overcoming
International Journal of Quality &
contemporary challenges and achieving and sustaining competitive advantage (Antony and Reliability Management
Gupta, 2019). Various structured continuous improvement (CI) approaches that were Vol. 36 No. 10, 2019
pp. 1699-1720
originally based on the philosophies and methods of Total Quality Management (TQM), © Emerald Publishing Limited
0265-671X
developed into Lean Manufacturing, Six Sigma and Lean Six Sigma (LSS) and have become DOI 10.1108/IJQRM-03-2019-0093
IJQRM a core strategic element in organizations to improve internal and external process
36,10 performance and to succeed in competitive markets (Adebanjo et al., 2016; McLean et al.,
2017; Tewari et al., 2017). Today, BPI initiatives such as Lean and Six Sigma are an integral
part of the overall business strategy for many organizations across a range of services and a
range of industry sectors (Adebanjo et al., 2016).
Most process improvement initiatives, conducted through projects have common
1700 characteristics (Anand et al., 2010; Tkáč and Lyócsa, 2010). Lean projects require an
understanding of systems-wide processes and utilize interdisciplinary teams (DeSanctis
et al., 2018; Stelson et al., 2017; Wackerbarth et al., 2015). Six Sigma is a project-driven
management approach (Bilgen and Şen, 2012; Arumugam et al., 2014, 2016) which employs
structured methods and tools to improve products, services and processes (Arumugam et al.,
2014; Laux et al., 2015; Tkáč and Lyócsa, 2010). Each Six Sigma project uses a structured
and organized approach, led by a project methodology expert and involving a team brought
together for the purpose of the project (Anand et al., 2009; Marzagão and Carvalho, 2016).
The same is true for LSS improvement projects (Iyede et al., 2018).
Despite the benefits that such structured approaches can bring, CI efforts are
consistently reported to have high failure rates (McLean et al., 2017). As these approaches
are inextricably linked to projects, success may be defined through successful project
management (Laux et al., 2015). As a result, project performance becomes an important
determinant for the successful implementation of CI initiatives such as Six Sigma
(Arumugam et al., 2014, 2016; Ray et al., 2013). The failure of Six Sigma and LSS projects can
undermine the impact of improvement initiatives on business performance (Antony and
Gupta, 2019). Bain and Company, a global management consultancy firm conducted a
survey on LSS and its benefits in 2008 and reported that 80 percent of 184 participating
companies claimed that LSS efforts were failing to drive the anticipated value and moreover
74 percent claimed that they were not gaining the expected competitive edge as they had not
achieved their saving targets from projects (CBIS, 2017). Chakravorty (2010), in his paper
that appeared on The Wall Street Journal, stated that an aerospace company which had
implemented more than 100 process improvement projects, that is, more than 50 projects,
had failed to generate lasting gains.
Despite organizational efforts, lean projects have not been consistently successful, often
resulting in delay, failure, abandonment or rejection (DeSanctis et al., 2018). In any large-
scale Six Sigma deployment comprising several project teams, project team failures are not
uncommon (Easton and Rosenzweig, 2012). Kuvvetli et al. affirm that although successful
Six Sigma projects are often widely reported in many journals, it is equally important to
understand the reasons for their failures.
Although scholars have investigated the critical success factors for the implementation
of CI initiatives (Easton and Rosenzweig, 2012; McLean et al., 2017; Yadav and Desai, 2017)
TQM (e.g. Seetharaman et al., 2006), Lean (e.g. Netland, 2016), Six Sigma (e.g. Brun, 2011)
and LSS (e.g. Bakar et al., 2015; Jeyaraman and Teo, 2010), only a few studies have
investigated the factors that lead to successful completion of process improvement projects
(Arumugam et al., 2016; Fernandes et al., 2019). From a practical standpoint, successful
completion of projects on time and their impact on project performance and subsequently
organizational performance cannot be overlooked. Since projects underpin CI approaches, it
is critical to understand the factors that lead to successful project performance (Arumugam
et al., 2014, 2016; Parast, 2011) and identify how we can reduce the risk of failure in CI
projects (Hadi-Vencheh and Yousef, 2016). It is beneficial to observe and analyze from the
perspective of project execution, the level of CI initiatives (Anand et al., 2009; Arumugam
et al., 2016). Most published articles are focused on the critical success factors of the initiative
and only a handful number of papers have reported about the key ingredients to make a
project successful in any process improvement or CI initiatives (Antony and Gupta, 2019).
This paper focuses on the reasons for failed Six Sigma projects in organizations and the Reasons for
authors argue that this is the first empirical study which makes an attempt to understand process
the reasons for such failures so that further research can be executed in mitigating the impact improvement
of such failures.
To prevent projects from failing and ending before completion, it is necessary to know project failures
the main reasons process improvement project failures. This paper presents the results of a
pilot study carried out with manufacturing specialists in Brazil to identify the primary 1701
reasons for project failures in process improvement related projects. If the primary reasons
for such failures are understood, a framework to mitigate such failures can be developed.
The primary contribution of this research lies with understanding and determining the
fundamental reasons behind process improvement project failures through an empirical
study. The results of this study can be extremely beneficial to senior managers and process
improvement champions in organizations to reduce the chances of project failures and have
some cash savings to the bottom-line. The next sections address the following topics:
Section 2 presents a review of existing literature on the reasons for process improvement
project failures; Section 3 covers the research methodology adopted for the study; Section 4
reports the results and key findings of the pilot study followed by discussion of the findings
in Section 5. The managerial implications and limitations are highlighted in Section 6 and
finally the conclusions and agenda for further research are outlined in Section 7.
2. Literature review
Studies on project failures are imperative as everyone, in general, is associated with various
financial and non-financial losses which can impede the development of other potential
projects. Additionally, learning from a project failure can play a key role in the planning and
monitoring of future projects to ensure the long-term success of any organization
implementing and sustaining CI initiatives such as Kaizen, Lean, Six Sigma or LSS.
Graves (2014) reported that many Six Sigma projects fail due to limited number of Six
Sigma experts in companies who can work closely with project teams to sustain the project
performance over time. He further highlighted the fact that the problem lies with not having
the optimal team size for projects as well as lack of motivation for team members from the
absence of Six Sigma expert. This finding is quite consistent with our findings of the study
which explcitly states that sub-optimal team size could lead to project failure. Moreover,
incompetency of team members is also reported to be a potential variable which results in
project failure in our findings. Mullavey (2006) presented some of the common reasons for
project failures in a typical Six Sigma initiative. He argued that many projects fail because of
insufficient resources (time, people) and poor participation among the team members.
Intersting enough, this is again found in our findings which suggest that partial coopertaion of
employees and their lack of engagement in problem solving scenarios is one of the primary
reasons for project failures. The authors would argue that most literature on project failures in
process improvement initiatives are written based on the experience of the author with no real
evidence with facts or data to back up their findings. The present study explicitly addresses
this gap by providing evidence on the reasons for process improvement project failures.
The purpose of this section is to outline the reasons for project failures in any process
improvement initiatives such as Lean, Six Sigma or LSS. However, the pilot study was
primarily focused on the reasons for Six Sigma projects rather than Lean or LSS projects.
The following ten reasons are developed from a research paper published by the first author
of this paper (Antony and Gupta, 2019).
2.5 Faulty selection of process improvement methodology and its associated tools/techniques
To guarantee the development of sustainable LSS projects, tools, techniques and methods
should be properly used and in the correct order (Iyede, Fallon and Donnellan, 2018;
Antony and Gupta, 2019). The selection of the most appropriate tools from the
toolbox as well as the methodologies and resources that best fit the problem are crucial to
a good project result (Antony and Gupta, 2019; Henderson and Evans, 2000). Several
improvement methodologies have been developed to address a specific type of operational
issue that encompasses a set of specific tools (Antony and Gupta, 2019) e.g. DMAIC and
the plan-do-check-act cycle (Mast and Lokkerbol, 2012). In the former, the phases are
clearly defined with associated supporting tools (Easton and Rosenzweig, 2012),
encompassing statistical and non-statistical approaches (Zu et al., 2008). Such supporting
tools need time to be correctly implemented (Antony and Gupta, 2019). The DMAIC
approach may not be appropriate for ill-structured problems in which subjective
perceptions and personal values are deemed important aspects for less extensive problem
solving processes (Mast and Lokkerbol, 2012).
3. Research methodology
Data were collected through an online survey which targeted Six Sigma practitioners and
project leaders in various manufacturing organizations including Six Sigma BBs, MBBs,
GBs and champions. An online survey method was selected, due to its low cost and the
ability to deploy the questionnaire in a standardized way, using self-administered
methods by the respondents (Couper and Miller, 2008). The questionnaire was piloted with
five academics, who are experienced in Lean and Six Sigma topics and who have
published extensively in peer-reviewed journals, as well as three Lean and Six Sigma
practitioners who have significant experience with projects. The purpose of the piloting
exercise was to identify those questions which needed improvement from a practical
standpoint as well as ensuring that none of the constructs were omitted by the researchers
(Forza, 2002).
In order to determine the relative importance of process improvement projects failure factors,
opinions were collected from 42 Six Sigma MBBs, BBs, GBs and champions. The sample
included professionals who each had experience in improvement projects within a manufacturing
industry environment. In sample selection, companies with a history of implementing CI
initiatives such as Lean and Six Sigma were identified. A total of 125 professionals were
contacted, and 42 responses were obtained (34 percent response rate) which is quite satisfactory
for pilot surveys of this nature (Antony and Fergusson, 2004; Antony, 2004).
measure variables. Several studies on CI initiatives also used the Likert scale (e.g. Antony
and Fergusson, 2004; Flynn et al., 1990; Hagen, 2010; Netland, 2016; Sin et al., 2015), which
is a scale widely used in survey research (Flynn et al., 1990; Hair et al., 2014).
Industrial sectors
2% 2%
5%
19%
7%
5%
17%
26%
17%
31%
26%
21%
21%
12%
10%
7%
Figure 3.
1–2 3–5 6–10 11–20 21–30 MORE THAN Experience in Six
PROJECTS PROJECTS PROJECTS PROJECTS PROJECTS 30 PROJECTS Sigma/Lean Six
Sigma projects
IJQRM In order to identify the existence of failures in CI projects, survey participants were asked
36,10 about project failure rates. Figure 4 shows the failure rates as observed by the experts who
worked on the improvement projects. While 23 percent of respondents perceive that over
30 percent of Six Sigma or LSS projects fail, 24 percent of respondents believe that the
failure rate is between 11–20 percent. The figure also highlights that only 14 percent of the
respondents believe that the failure rate is less than 5 percent. This indicates that further
1710 studies need to be conducted to identify the reasons for project failure.
Participants were questioned about the failure rate at each stage of the improvement
cycle (DMAIC), leading to the interruption of the Lean and LSS projects (Figure 5).
In observing the failure rate whilst considering DMAIC phases, although approximately
50 percent of the respondents identified that there are less than 5 percent of projects failing
in each of the phases, between 24 and 31 percent of respondents consider that failure rate
varies between 6 and 10 percent, mainly in the measure, analyze and improve phases.
19%
14%
14%
7%
2%
Figure 4.
Continuous
improvement project
failure rate LESS THAN 6–10% 11–20% 21–30% 31–40% 41–50% MORE
5% THAN 50%
57%
52%
52%
48%
31%
26%
24%
17%
17%
17%
14%
14%
12%
10%
10%
Figure 5.
7%
5%
2%
2%
2%
2%
2%
2%
2%
2%
2%
2%
2%
0%
0%
0%
0%
0%
considering DMAIC
phases
DEFINITION MEASURE ANALYSE IMPROVE CONTROL
During the analyze phase, 17 percent of respondents believe that the failure rate varies Reasons for
between 11–20 percent. Additionally, 17 percent of respondents believe that more than process
50 percent of projects fail during the control phase, i.e. results are not sustained over time. improvement
The results suggest that project failures occur and that there are particular phases of the
DMAIC cycle that are crucial for generating good project results and consequently positive project failures
results and support for the improvement initiative. The preliminary results of this pilot
study indicate that the measure, analyze, improve and control steps are critical stages to 1711
prevent failure which could result in the loss of several thousand dollars or even millions of
dollars in matured companies of BPI initiatives, depending upon the size of the organization
and the number of Six Sigma projects carried out.
5. Discussion
The reasons provided for CI projects failure are not well explored in the literature and are
limited in terms of empirical studies (Arumugam et al., 2016). The CI approaches, such as
Lean, Six Sigma and LSS are directly related to the execution of projects and success may be
IJQRM Failure factors Variables Average
36,10
1. Lack of commitment 1.1 Lack of involvement of top management in conceptualization 3.36
and support from top (goal setting and project selection)
management 1.2 Lack of top management commitment in project planning 3.62
(resource allocation)
1.3 Lack of top management commitment in project implementation 3.45
1712 (monitoring and controlling)
1.4 Project sponsors (or senior managers) are not committed to aligning 3.17
project objectives with the corporate strategy
1.5 Project champions (or heads of various business functions) 3.12
are not committed to aligning project objectives with the
corporate strategy
1.6 Lack of a systematic and transparent methodology for project 2.69
selection, prioritization, and project tracking by the management
2. Poor communication 2.1 Barriers in communication surrounding the project design and 2.64
practices implementation phase
2.2 Lack of development of communication strategies or practices 2.74
during the project execution phase
2.3 Lack of communication among the various project stakeholders 3.14
2.4 Lack of communication about the progress of the project between 2.76
the project leaders and the project champions or sponsors
2.5 Poor communication (i.e. timeliness, accuracy and usefulness 2.93
of information)
2.6 Poor communication among team members (i.e. communication 2.90
openness, discussion efficiency, and discussion effectiveness)
2.7 Lack of using information and communication technologies for 2.40
knowledge sharing across various projects
3. Incompetent team 3.1 Lack of a common goal, and interdependence among team members 2.93
3.2 Lack of adequately skilled team members 3.14
3.3 Lack of problem solving expertise/knowledge by team members 2.98
3.4 Lack of motivation on behalf of the team members 2.95
3.5 Lack of establishing and optimizing the project team based on 2.88
detailed task descriptions and allocation analysis
3.6 Lack of complementing skill among project members 2.69
3.7 Lack of learning new skills to respond to changes in the 2.48
business environment
3.8 Lack of project leadership skills necessary to lead the team 3.29
4. Inadequate training 4.1 Lack of strategies that support organic learning between projects 2.62
and learning through various training programs and experience-sharing sessions
4.2 Not taking into account the characteristics of the team members in 2.98
order to determine types of training and their content
4.3 The company does not continually review the links between skills, 2.90
performance, and training programs
5. Faulty selection of 5.1 There is no selection of the methodology that best fits the 2.57
process improvement project problem
methodology and its 5.2 There is no tool/technique selection process that best fits the 2.62
associated tools/ project problem
techniques 5.3 There isn’t enough time being allocated to data an information 3.21
collection in order to deploy tools and techniques effectively
5.4 Tools are applied in the incorrect order 2.50
5.5 There is inadequate time to implement the process improvement 2.98
methodologies
5.6 There is overuse of tools and techniques 2.31
5.7 There is underuse of tools and techniques 2.60
Table III.
Average of the
variables (continued )
Failure factors Variables Average
Reasons for
process
6. Inappropriate rewards 6.1 There is a lack of policies in place to recognize and reward success 2.88 improvement
and recognition 6.2 There is lack of incentives for project members concerning 2.90
system/culture appropriate recognition and rewards project failures
7. Scope creep 7.1 There is no collaboration between project champions and project 2.76
leaders (usually Six Sigma GB or BB) to define the scope of the project
7.2 There is a lack of scope management techniques in the project 2.50 1713
planning stage
7.3 There is a lack of proper documentation for the scope of the project 2.43
outlining the responsibilities of each member
8. Sub-optimal team size 8.1 Inadequate size of the project team in relation to the scope, duration 2.40
and composition and complexity of the projects
8.2 There is no optimization for the team size 2.45
8.3 Lack of enough time to understand the different personalities of each 2.81
member for better team cohesion
8.4 Lack of facilitators with key positions in the organization to ensure 3.40
management commitment
8.5 Inadequate representation from relevant functional units in the 2.93
project team
8.6 Lack of participation from MBB in the team as senior coaches with 2.79
junior coaches (BB and GB) who manage individual project teams
9. Inconsistent 9.1 There is inconsistent monitoring and control of the project processes 2.93
monitoring and by a process expert
control (lack of expert 9.2 There is not a permanent process improvement expert who has a 2.90
supervision) reasonable understanding of the business organization process for
consistent monitoring and control
9.3 Lack of a monitoring system designed and developed to track the 2.88
progress of a project in real-time
9.4 The output report of the project monitoring is not consistently 2.86
disseminated (visual display at the workplace, seminar, meeting,
interim report etc.)
10. Resistance to change 10.1 Lack of employee participation and involvement in problem solving 3.19
(partial cooperation 10.2 The management does not understand the causes of employee’s 3.38
by employees) resistance or underperformance, and does not take immediate action
10.3 There is employee’s resistance to change 3.67
10.4 There is no integration of the employees’ opinions and cooperation 2.83
in each phase of the DMAIC
10.5 There are no strategies to convince resistant employees to maintain 3.26
a positive attitude regarding process improvement projects Table III.
defined through successful project management (Laux et al., 2015). Therefore, this study
aims to contribute to filling this literature gap, especially since there are direct managerial
implications in practitioners’ awareness of the reasons for process improvement project
failures. We identify and describe ten factors that can influence the failure of process
improvement projects based on the literature. These factors were then investigated
empirically through an online pilot survey, completed by specialists who had experience in
process improvement projects in manufacturing organizations.
The findings of the study suggest that improvement projects have a moderate failure rate
in manufacturing companies and moreover the failure rate is most common in the measure,
analyze, improve and control phases of the Six Sigma problem solving methodology. This
finding was a big surprise to the authors as practitioners of Six Sigma and LSS and moreover
a few studies have reported that the “Define Phase” in the Six Sigma problem solving
methodology is a very critical phase (Pyzdek and Keller, 2018; Voehl et al., 2014). One of the
biggest concerns for many project leaders and Six Sigma practitioners is that the improved
IJQRM Construct (factor) Variables Average
36,10
Resistance to change (partial cooperation 10.3 There is employee’s resistance to change 3.67
by employees)
Lack of commitment and support from 1.2 Lack of top management commitment in project 3.62
top management planning (resource allocation)
Lack of commitment and support from 1.3 Lack of top management commitment in project 3.45
1714 top management implementation (monitoring and controlling)
Sub-optimal team size and composition 8.4 Lack of facilitators with key positions in the 3.40
organization to ensure management commitment
Resistance to change (partial cooperation 10.2 The management does not understand the causes 3.38
by employees) of employee’s resistance or underperformance, and does
not take immediate action
Lack of commitment and support from 1.1 Lack of involvement of top management in 3.36
top management conceptualization (goal setting and project selection)
Incompetent team 3.8 Lack of project leadership skills necessary to lead 3.29
the team
Resistance to change (partial cooperation 10.5 There are no strategies to convince resistant 3.26
by employees) employees to maintain a positive attitude regarding
process improvement projects
Faulty selection of process improvement 5.3 There is not enough time being allocated to data an 3.21
Table IV. methodology and its associated tools/ information collection in order to deploy tools and
The main variables techniques techniques effectively
pointed as causes of Resistance to change (partial cooperation 10.1 Lack of employee participation and involvement in 3.19
project failures by employees) problem solving
performance for many projects could not be sustained over time in the control phase which
potentially implies significant resource (i.e. time in particular) loss and increased cost. The
failures within the control phase indicate that the results are not sustained and this may
destabilize the overall improvement approach, causing the organization to give up on the CI
initiative (Snee and Hoerl, 2018; Antony et al., 2018).
The main findings of the study involve the identification of the construct and highlighted the
main reason for failure as resistance to change (partial cooperation by employees). Although this
finding has been identified in many books and articles, it was never empirically proven with data
collated from practitioners of Six Sigma. Albliwi et al. (2014) reported the critical failure factors of
LSS and one of the factors identified in their systematic review was resistance to change across
the middle management level. McLean and Antony (2014) also highlighted the importance of
resistance to change at the organizational level in their study on the failure of CI initiatives, such
as Lean and Six Sigma. The main variables of this failure are: resistance to change by employees,
lack of employee involvement in problem solving and lack of understanding, actions and
strategies by management to convince resistant employees to maintain a positive attitude. This
suggests that one of the main reasons for failure involves a change in culture, moving toward a
culture of improvement in which people understand the importance of and are willing to
contribute to improvement projects. The culture shift is a challenging task for managers.
Top management is also a critical factor for failure, and as already pointed out as a
prominent factor of success (Netland, 2016; Brun, 2011), the lack of direct commitment in the
projects leads to the failure and the waste of resources. Management plays a crucial role in
monitoring projects, from the selection and application of resources to post-implementation
and sustainability of results. Top management can also play a role regarding the resistance
to change and senior managers should understand the reasons and develop remedial actions
to mitigate the causes of resistance.
The team also compromises on project success, where it is necessary to develop the team
members’ skills, including problem solving. The composition of the team can be construed
as a barrier, as the team ideally should be chosen for the specific project purpose and Reasons for
members’ skills should be complementary. Snee and Hoerl (2018) emphasize the importance process
of team formation in the execution of Six Sigma Black Belt and Green Belt projects. The best improvement
approach to forming the team is to create it in consultation with the Six Sigma project
champion and the managers to whom the prospective team members report the progress of project failures
the projects. Inappropriate rewards and recognition systems can also compromise the
development of the project by not motivating the members to execute it. Additionally, the 1715
reward system may cause employees, who are not part of the Belt hierarchy, to feel
underappreciated and they can misinterpret the progress of the project due to a lack of data
and/or information, and perhaps also perceived barriers to the realization of projects.
Inconsistent monitoring and control is also a factor for failure and is related to the most
troubling stage of DMAIC for project failure, which is the control step. McLean and Antony
(2014) highlighted in their research that one of the failure factors for implementation of Lean
and Six Sigma is the lack of feedback and lack of effective monitor and control in the entire
project life cycle.
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Further reading
Hadi-Vencheh, A. and Yousefi, A. (2018), “Selecting Six Sigma project: a comparative study of DEA and
LDA techniques”, International Journal of Lean Six Sigma, Vol. 9 No. 4, pp. 506-522.
Corresponding author
Jiju Antony can be contacted at: j.antony@hw.ac.uk
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