Unlocking the potential: empirical analysis of enablers, barriers, benefits and technologies for integrating Industry 4.0 and Lean Six Sigma in manufacturing organisations

Zulfiqar, Maryam, Sony, Michael, Bhat, Shreeranga, Antony, Jiju, Salentijn, Willem, & McDermott, Olivia. (2024). Unlocking the potential: empirical analysis of enablers, barriers, benefits and technologies for integrating Industry 4.0 and Lean Six Sigma in manufacturing organisations. The TQM Journal, 36(8), 2360-2382. doi:10.1108/TQM-05-2023-0130

Abstract

Purpose: The integration of Lean Six Sigma and Industry 4.0 is in the nascent stage and promises to achieve new optimums in operational excellence. This study aims to empirically examine the enablers, barriers, benefits, and application of Industry 4.0 technologies in Lean six Sigma and Industry 4.0 integration. Design/Methodology/Approach: A pilot survey was chosen as an appropriate methodology, as Lean six Sigma and Industry 4.0 integration is still budding. The survey targeted senior quality management professionals, quality managers, team leaders, Lean Six Sigma Black Belts, and operations managers to collect the relevant research data. The questionnaire was sent to 200 respondents and received 53 valid responses. Findings: This study reveals that "top management support" is an essential enabler for Lean Six Sigma and Industry 4.0 integration. The most significant barrier was "poor understanding of data analysis" and "lack of top management support". The findings further illustrated that Lean Six Sigma and Industry 4.0 integration resulted in greater efficiency, lower operational costs, improved productivity, improved customer satisfaction, and improved quality. Regarding Industry 4.0 technology integration at different phases of Lean Six Sigma, we noticed that Big Data Analytics and Artificial Intelligence are the most prominent technologies used in all phases of Lean Six Sigma implementation. Originality/value: Lean Six Sigma and Industry 4.0 integration was studied at a conceptual level. This is the first empirical study targeted toward understanding the Lean Six Sigma and Industry 4.0 integration. In addition, this study investigates the application of widely used Industry 4.0 technologies in different phases of Lean Six Sigma. Practical Implications: The outcomes of this study can be useful for organisational managers to understand the enablers and barriers before integrating Lean Six Sigma and Industry 4.0 for adoption in their organisations. Secondly, it helps to convince top management and human resource personnel by providing a list of benefits of Lean Six Sigma and Industry 4.0 integration.

Publisher

Emerald

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CC BY-NC-ND 3.0 IE

cbn

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