Integrating Lean Six Sigma and Industry 4.0: developing a design science research-based LSS4.0 framework for operational excellence

Abstract

Acknowledging the potential benefits of integrating Industry 4.0 techniques into Lean Six Sigma-oriented process improvement initiatives, the current literature lacks a comprehensive guideline for the systematic incorporation of Industry 4.0 within Lean Six Sigma practices. To fill this gap, we have developed the LSS4.0 framework, employing a design science research approach. This framework serves as a structured integration model for Industry 4.0 and Lean Six Sigma, aimed at assisting organizations in their journey towards LSS4.0 implementation. Through iterative development and collaboration with experts in both Lean Six Sigma and Industry 4.0, the framework and its associated 14-step implementation process underwent evaluation using action research-based semi-structured interviews and demonstrations, featuring case studies from the automotive (F2) and mining (F3) industries. The outcomes demonstrated substantial operational enhancements, including reduced defects, improved on-time delivery, a 95% first-pass yield in F2, a 20% boost in energy efficiency, an increase in equipment effectiveness from 75 to 85% in mining operations, and a notable 30% decrease in unplanned downtime incidents, contributing to improved productivity and operational efficiency while reducing maintenance costs. This research significantly advances knowledge in Industry 4.0 and Lean Six Sigma, offering valuable insights and making a meaningful contribution to the broader field of quality management.