Evaluation of the Critical Failure Factors of Process Improvement Methodologies: An AHP Approach

This study aims to evaluate the critical failure factors (CFFs) of process improvement (PI) projects, providing an initial understanding of the most impactful factors during PI implementation. Conducting an extensive literature review encompassing five prominent PI methodologies, Kaizen, Lean, Six Sigma, Lean Six Sigma, and Agile, revealed 39 CFFs contributing to PI failures. To manage this extensive set of factors, we utilize the Pareto analysis followed by the Analytical Hierarchy Process (AHP) model to assign weight to each factor and prioritize them accordingly. Five PI experts were involved in the pairwise comparison of the CFFs to examine the most influential factors. The top-ranked CFFs highlighted for PI initiatives were “Lack of top management support”, “Lack of clear vision/strategy for PI and future plans”, “Resistance to change”, “Lack of motivation, encouragement and reward” and “Lack of alignment between strategic objectives and PI project scope”. The outcomes of this work serve as a valuable tool for policymakers and PI professionals, offering a means to diagnose, evaluate, and address highly ranked CFFs, ultimately minimizing the risk of PI project failure.