Citation :

Deepak Kothari, Sunil Kumar D, Venkatesh N, "Six Sigma Adoption in Karnataka: A Review of Success Factors and Six Sigma Challenges in Manufacturing and Service Industries," International Journal of Engineering Trends and Technology (IJETT), vol. 74, no. 3, pp. 25-42, 2026. Crossref, https://doi.org/10.14445/22315381/IJETT-V74I3P103

Abstract

Six Sigma is a sound quality improvement technique that seeks perfectionality almost to the letter in organisational procedures. It is also efficient in the sense that it reduces the non-value adding activities and thus maximises resource utilisation. In business sectors like manufacturing, Six Sigma has greatly led to a minimization of flawed products and an enhancement of the working processes. Equally, its use in the service industry has increased customer experiences and reduced IT downtimes. Using the statistical means and the data-based analysis of defects, businesses can detect the areas of improvement and provide specific solutions. Effective communication, employee involvement, and top management commitment are critical success elements in Six Sigma deployment. Nevertheless, resistance to change, resource availability, and insufficient training are among the issues that can act as obstacles to the process. These challenges notwithstanding, the successful implementation of Six Sigma has resulted in significant improvement in various sectors, such as improved customer satisfaction, cost savings, and improved revenue. An example is Motorola, which developed Six Sigma, and it claimed to save over 17 billion dollars within the initial five years of its application. An example of sugar plants in Karnataka shows that Six Sigma enhanced the efficiency of processes and minimized the level of defects, which ultimately led to increased financial performance and customer satisfaction. The research showed that 49 percent of the respondents had realized financial benefits, whereas 55.5 percent had seen an improvement in productivity due to Six Sigma programs. This is in line with the research findings in other sectors where poor quality costs have been reduced and operations streamlined using Six Sigma to facilitate economic growth.

Keywords

Six Sigma, Quality Improvement, Process Improvement, Manufacturing and Service Industry, Critical Success Factors (CSFs).

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