IMPACT OF 6S PRINCIPLES ON EMPLOYEE PERFORMANCE: EVIDENCE FROM AN AUTOMOTIVE LIGHTING MANUFACTURER IN CHENNAI, INDIA

Authors:

Dr. M. BEULAH VIJI CHRISTIANA, Mr PREM KUMAR A

Dr. M. Beulah Viji Christiana M.A,M.Phil,M.B.A., Ph.D Professor Panimalar Engineering College, Chennai – 600123 Prem Kumar A , Student, Panimalar Engineering College, Chennai – 600123

Abstract — This study examines the impact of 6S principles — Sort, Set in Order, Shine, Standardize, Sustain, and Safety — on employee performance at an automotive lighting manufacturer in Chennai, India. Using a structured questionnaire administered to 140 employees selected via convenience sampling from a population of 200, the study assesses employee perceptions of 6S practices, their integration with human resource (HR) functions, and outcomes related to workplace efficiency, safety, and continuous improvement (Kaizen). Statistical analysis employed non-parametric methods including the Kruskal–Wallis H test, Mann–Whitney U test, Chi-square test, Spearman's rank correlation, weighted average analysis, and interval estimation. Findings reveal that 81% of respondents are aware of 6S practices, while 46% confirm that 6S improves work efficiency. Sort emerged as the most impactful 6S element (weighted average: 4.16), and Reduced Accidents ranked highest among safety improvements. No significant gender-based differences in 6S awareness were observed, though age- group variations in perceptions of work efficiency were statistically significant. The study concludes that systematic 6S implementation, reinforced through HR-led training, appraisal linkages, and incentive mechanisms, substantially enhances operational discipline, safety compliance, and employee motivation in manufacturing settings.

Keywords — 6S methodology, employee performance, workplace efficiency, lean manufacturing, safety management, Kaizen, HR practices, automotive industry.