Lean Six Sigma and Industry 4.0 integration for Operational Excellence: evidence from Italian manufacturing companies

Abstract

This research investigates a possible integration between Lean Six Sigma (LSS) tools and principles and Industry 4.0 technologies. The aim is the development of a new pattern for Operational Excellence through the grounded theory methodology. Data collection involved interviewing Italian manufacturing managers in ten case organisations as well as a direct observation of practices linked to Industry 4.0 and LSS integration at one of the selected case organisations. Results of the study aligns with preliminary literature supporting LSS providing platform to achieve effective outcome from Industry 4.0 application. The integration needs reinvented mapping tools and implies a horizontal integration and a vertical, end-to-end integration. The latter requires the company to reengineer the ERP modules, while in the horizontal integration the real ultimate goal is to reach a complete automatic synchronisation of the processes named Autonomous Process Synchronisation. Moreover, all the data gathered from production processes and offices needs the development of new analytics at all levels. This is amongst first few studies that answers how to achieve integration between LSS and Industry 4.0 technologies and thus have several research and managerial contributions in advancing operational excellence research.

Keywords:

• Lean Six Sigma
• Industry 4.0
• Operational Excellence
• integration
• manufacturing
• case studies

Disclosure statement

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

Additional information

Notes on contributors

Andrea Chiarini

Andrea Chiarini is Senior Lecturer of Operations Management at the University of Verona – Italy. He has been a consultant and trainer to a range of manufacturing and service firms on TQM, Lean Six Sigma and Industry 4.0. Along with other partners he set up in Italy Chiarini & Associati a consulting firm dedicated to Lean Production, Six Sigma, IATF 16949, Industry 4.0 and Management Accounting. He has taught in Post-Graduate courses and short courses for Executives. Senior Member of the American Society for Quality (ASQ), he serves in the editorial boards of Business Strategy and the Environment, Leadership in Healthcare, the Journal of Manufacturing Technology Management and the TQM Journal

Maneesh Kumar

Maneesh Kumar is a Professor of Service Operations at Cardiff Business School, Cardiff University. He conducts cross-disciplinary research in the area of Operational Excellence including topics such as Lean Six Sigma (LSS), Process/Service Innovation, Industry 4.0, Circular Economy and Knowledge Management within SMEs, Automotive Industry, Service Industries and Public Sector organisations. This has resulted in publications of over 120 journals and conferences papers, edited books, and conference proceedings. He is an active member of EUROMA. He has initiated a first practice based forum on Lean Green and Innovation (iLEGO) that brings practitioner community together to have engaged discussion on synergies and misalignments between the three topics and promote cross learning between different industries. He has been involved in delivering LSS training up to Black Belt level and delivered several workshops on LSS application in different type and size of industries including Kwik-Fit Insurance Services, Standard Life, Admiral, Principality, Bakkavor Group, Norbert Dentressangle, Norgine Ltd., Celsa Steel, NHS Grampian, NHS Sheltand, Edinburgh City Council, Aberdeenshire Council, and Tata Motors. He is also a regular speaker at International Conferences and Seminars on Operations Management, LSS & Operations Excellence.