Combining Lean Six Sigma and agile approach to optimize order management: action research in a Brazilian company

Abstract

Purpose This paper aims to assess the combined application of Lean Six Sigma and agile approach for optimizing operational processes of order management in the seed industry. Design/methodology/approach This study is based on an action research case conducted in a multinational Brazilian Seeds Business enterprise. This paper reports on the application of the Lean Six Sigma define-measure-analyze-improve-control (DMAIC), using the steps of DMAIC cycle as a sprint of agile approach. The methodology involves outlining an operational process through sequential activities, each associated with a cycle time, equivalent number of full-time employee and number of orders. Performance metrics for the order management process include continuous monitoring of these activities, using monitoring systems, management software and manual records to collect data. Findings The findings reveal significant improvements in critical-to-quality measures related to customer care, planning and logistics. The implementation of the DMAIC methodology and agile approach resulted in tangible enhancements in cycle time, defects per opportunities and overall process efficiency. The results allow the classification of defects, the identification of their causes and, consequently, the presentation of a control plan to mitigate these problems. Furthermore, the study identifies key causes of operational issues and proposes a prioritized action plan. Research limitations/implications The limitation of this research is its restriction to a single case. The external validity of the results and generalizability to other organizational contexts may be compromised due to the lack of case diversity. The fact that the research focuses on a single company, even if it is a large multinational company, may limit the applicability of the findings to different sectors, sizes and organizational structures, which may be an opportunity for future research. Practical implications The findings suggest that the integrated approach of DMAIC and agile methodology contributes to a culture of continuous improvement and operational efficiency. The systematic collection and analysis of data enhance evidence-based decision-making, providing a robust foundation for strategic and operational choices. Moreover, the successful integration of methodologies presents a comprehensive framework applicable to diverse organizational challenges. Originality/value The paper applies action research to understand and address operational challenges, emphasizing practical solutions. The integration of DMAIC and agile enhances the depth of process analysis, enabling the identification, implementation and control of improvements. This study offers a significant contribution both to practitioners, providing practical implications, and to academics, enriching the Lean Six Sigma and agile body of knowledge.