Integrating Lean Six Sigma and Industry 4.0: developing a design science research-based LSS4.0 framework for operational excellence: Production Planning & Control: Vol 0, No 0

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.

Keywords:

Acknowledgements

The authors thank all the respondents in the participating companies and top management for the permission to carry out the research. We also thank the reviewer and editors for constructive suggestions which have improved the paper.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Notes on contributors

Dounia Skalli

Dounia Skalli, a research scholar at the Laboratory of Innovation and Industrial Management at Hassan First University of Settat, Morocco, holds a background as an industrial engineer coupled with over 8 years of professional experience as a QSE Manager in the Oil and Gas industry. She is a certified IRCA lead auditor. Dounia has made significant contributions to the academic realm with articles published in leading and peer-reviewed journals. Her research focus encompasses a broad spectrum, including Lean Six Sigma, Industry 4.0, Operational Excellence, Sustainability in the 4.0 era, Circular Economy, and Digital Maturity.

Anass Cherrafi

Anass Cherrafi is an Associate Professor at EST-Safi, Cadi Ayyad University, Morocco. Holding a Ph.D. in Industrial Engineering, he has nine years of industry and teaching experience. In 2022, Anass Cherrafi has received the Moroccan Scopus award from the ministry of higher education, CNRST and Elseiver as the first research in Morocco in “Business, Management, and Accounting”. He has published a number of articles in leading international journals including International Journal of Production Research, International Journal of Production Economics, Production Planning and Control, Business Strategy and the Environment, Journal of Cleaner Production and many others. He has been a Guest Editor for special issues of various international journals. His research interests include Industry 4.0 / 5.0 , Green manufacturing, Circular Economy, Lean Six Sigma and Supply Chain Management.

Abdelkabir Charkaoui

Abdelkabir Charkaoui PhD in Logistics and SCM. Professor of Operations Management and SCM at Hassan I University, Faculty of Science and Technology - Settat, Morocco. Department of Mechanical Engineering, Laboratory of Industrial Management and Innovation (LIMII). He is the head of the research team: Supply Chain Management and Operations Management and the editor in chief for the Journal of Operations Management, Optimization and Decision Support (JOMODS). His research areas of interest are operations management, logistics performance, and Lean Manufacturing maturity.

Andrea Chiarini

Andrea Chiarini received a Master’s Degree in Electronic Engineering and a Post Graduate Diploma inBusiness Administration from Bologna University- Italy. He has also been awarded a Master of Arts (MA) inSocial Science and Research Methods (Organisation and Management)and aPhD in‘TQM and Business Excellence’ from Sheffield Hallam University, UK.He is a Professor of Operations Management at the University of Verona and the University Bocconi – Milan, Italy. He has researchedStrategic Management, Operations Management, Industry 4.0, TQM, Lean Six Sigma, Production Management, and CSR. He is a senior partner at Chiarini & Associati, an Italian consulting firm dedicated to Operations Management whichhas carried outprojects with worldwide companies such as ABB, Barilla, Bulgari, Bridgestone, Continental, Donaldson, Ducati Motor Holding, Engie, Lamborghini, Leonardo, Fiat, Ferrari, Parmalat, Tyco, Tetrapak, etc. He is a senior member of the American Societyfor Quality (ASQ) and Associate Editor of the journal Business Strategy and the Environment.

Alireza Shokri

Alireza Shokri is an Associate Professor (Reader) in Operations and Supply Chain Management and the subject group leader of “Operations and Supply Chain Management” in the Newcastle Business School at Northumbria University in the UK. Prior to the current position, Alireza was the programme leader for the BA (Hon) International Business Management Programme. Before joining Newcastle Business School in 2011, Alireza had different practitioner roles including supply chain manager, quality manager, and ISO9001 internal consultant in food sector. Alireza completed his PhD in Lean Six Sigma application within food distribution SMEs in 2011 and since then he is working as an academic. Alireza is currently leading the “Global Operations and Supply Chain Competitiveness” Research Interest Group with academic members across the globe. Alireza is also member of editorial board for the “International Journal of Lean Six Sigma”. As the principal investigator, Alireza currently led different projects funded by the British Academy and Innovate UK. He is also a co-investigator of a multi-disciplinary global EU-funded (1m Euros) project as part of “Horizon 2020” called “GETM3 Project”. Alireza’s research focuses on Lean Six Sigma and its application in service and manufacturing, Lean Six Sigma integration with Supply Chain Management, Industry 4.0, HR and Sustainability, Supply Chain Quality Management and process improvement and Lean Management. His research has been published in international leading/excellence level journals in his research including “International Journal of Operations and Production Management (ABS 4*). Alireza is the member of Chartered Quality Institute (CQI) as the practitioner. Alongside that, Alireza is the Fellow of Higher Education Academy (FHEA). Alireza is also a certified Lean Six Sigma Green belt with professional capability of leading on lean Six Sigma projects. Alireza is keen on working with local, national and international businesses and he is the strong believer on “Research in Practice”.

Jiju Antony

Jiju Antony is recognized worldwide as a leader in Lean Six Sigma methodology for achieving and sustaining process excellence. He is currently serving as a Professor of Industrial and Systems Engineering at Khalifa University in Abu Dhabi, UAE. He is a Fellow of the Royal Statistical Society (UK), Fellow of the Chartered Quality Institute (CQI), Fellow of the Institute of Operations Management (FIOM), Fellow of the American Society for Quality (ASQ), Fellow of the Higher Education Academy, Fellow of the International Lean Six Sigma Institute, Fellow of the Institute of the Six Sigma Professionals (ISSP) and an Academician of the International Academy of Quality (IAQ). He is a Certified Lean Six Sigma Master Black Belt and has trained over 1200 people as Lean Six Sigma Yellow, Green and Black Belts from over 20 countries representing over 170 organisations in the last 10 years. Professor Antony has coached and mentored several Lean Six Sigma projects from various companies in the UK ranging from manufacturing, service to public sector organisations including the NHS, City Councils, NHS 24, Police Scotland, ACCESS, Business Stream, and a number of Universities. Professor Antony has authored over 500 journal, conference and white papers and 12 text books. He has won the outstanding contribution to Quality Management Practice Award in 2019 from the Chartered Quality Institute (UK); Life time Achievement Award for his contribution to Lean Six Sigma from the International Lean Six Sigma Institute (UK) in 2020 and Outstanding Contribution to Six Sigma Practice award from the Institute of Six Sigma Professionals, UK in 2021. His book on Ten Commandments of Lean Six Sigma: a practical guide for senior managers has won Walter Mazing Book Price in 2021 (International Academy of Quality, USA) and Crosby Medal (American Society of Quality, USA) in 2022.

Jose Arturo Garza-Reyes

Jose Arturo Garza-Reyesis a professor of Operations Management and Head of the Centre for Supply Chain Improvement at the University of Derby, UK. He is actively involved in industrial projects where he combines his knowledge, expertise and industrial experience in operations management to help organisations achieve excellence in their internal functions and supply chains. He has also led and managed international research projects funded by the British Academy, British Council, European Commission and Mexico’s National Council of Science and Technology (CONACYT). As a leading academic, he has published over 200 articles in leading scientific journals, international conferences and seven books. Prof. Garza-Reyes is Associate Editor of the Int. J. of Operations and Production Management, Associate Editor of the Journal of Manufacturing Technology Management, Editor of the Int. J. of Supply Chain and Operations Resilience and Editor-in-Chief of the Int. J. of Industrial Engineering and Operations Management. Areas of expertise and interest for Professor Garza-Reyes includeOperations and Production Management, Supply Chain and Logistics Management, Lean and Agile Operations and Supply Chains, Sustainability within the context of Operations and Supply Chains, Circular or Closed-Loop Operations and Supply Chains, Sustainable and Green Manufacturing, Industry 4.0 technologies application in operations and supply chains, Lean Management, Quality Management & Operations Excellence and Innovation Management.

Monika Foster

Monika Foster is a Professor in Business Education and Head of Department Marketing, Operations and Systems at the Faculty of Business and Law and Professor of Business Education. Her previous role was the Head of Sunderland Business School. Professor Foster has worked in Business Schools in the UK, Europe and Far East for over 30 years and led a number of international, cross-institutional and interdisciplinary projects to scope and design mechanisms for assisting students with transitions, especially international transitions and relationship building. Monika’s research interests lie in cross-cultural management, employability, internationalization of higher education, intercultural aspects, and leadership and change management (HR). Professor Foster has previously led Research Centre for Management Learning and Business Education. Monika’s external recognition includes the award of National Teaching Fellow and Principal Fellow of HEA and a title of Visiting Professor in a number of universities, as well as Editorial roles including as Co-Editor on Perspectives On, and Dynamic Conversations with Chartered ABS.