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CONTINUOUS IMPROVEMENT PRACTICES OF THE LEAN SIX SIGMA PROCESS APPROACH WITHIN AN ENGINEERING PRODUCT TESTING CAPABILITY

    Zukisa Nkonzo, Andre Vermeulen, Jan Harm C Pretorius

Abstract

- The study assesses the impact of continuous improvement initiatives on performance. These initiatives were implemented to enhance the Lean Six Sigma process approach within an engineering product testing capability, thereby reducing long product testing turnaround and cycle times. The research methodology employs an interpretive approach, using a structured, open-ended questionnaire in sixteen focus group interviews. A descriptive approach using a structured online questionnaire administered to 100 engineering product testing personnel was also considered. Based on interview responses and a review of the literature, three major themes and nine subthemes were identified for qualitative data analysis. The paper presents 12 findings: three from an interpretive analysis and nine from a descriptive analysis. These findings indicate that engineering product-testing capabilities partially apply Lean Six Sigma principles; however, excessive turnaround and cycle times are observed. The paper obtained information from twenty-six product-testing capability facilities within a self-revenue-generating organisation. The study examines the practical implications of the current adopted performance status quo and presents several strategies to enhance output performance for the benefit of organisations. It is recommended that product-testing capabilities consider identified improvement opportunities and recommend solutions to address the causes and effects that lead to further increases in excessive turnaround and cycle times. Furthermore, the study's contribution identifies opportunities to strengthen state-owned revenue-generating product-testing capabilities, research-institution testing capabilities, and industrial and medical laboratories by applying or enhancing Lean Six Sigma to improve their product-testing performance.

Keyword : continuous improvement, cycle times, lean, six sigma, lead times, turnaround times.

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July 25, 2026
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This work is licensed under a Creative Commons Attribution 4.0 International License.