2 research outputs found
Integration of Industry 4.0 technologies into Lean Six Sigma DMAIC: a systematic review
This review examines which Industry 4.0 (I4.0) technologies are suitable for improving Lean Six Sigma (LSS) tasks and the benefits of integrating these technologies into improvement projects. Also, it explores existing integration frameworks and discusses their relevance. A quantitative analysis of 692 papers and an in-depth analysis of 41 papers revealed that “Analyse” is by far the best-supported DMAICs phase through techniques such as Data Mining, Machine Learning, Big Data Analytics, Internet of Things, and Process Mining. This paper also proposes a DMAIC 4.0 framework based on multiple technologies. The mapping of I4.0 related techniques to DMAIC phases and tools is a novelty compared to previous studies regarding the diversity of digital technologies applied. LSS practitioners facing the challenges of increasing complexity and data volumes can benefit from understanding how I4.0 technology can support their DMAIC projects and which of the suggested approaches they can adopt for their context
DMAIC 4.0 - innovating the Lean Six Sigma methodology with Industry 4.0 technologies
Lean Six Sigma (LSS) is a continuous improvement methodology that emerged around
2000 (George and George, 2002; Snee, 2010). It combines the strengths of two
methodologies, Lean and Six Sigma, into an effective process and quality improvement
framework. Although many organisations have successfully applied LSS over the past
two decades, over 60% of Lean and Six Sigma implementations have failed (Albliwi et
al., 2014; Sony et al., 2020c), and, accordingly, a significant number of improvement
projects. Consequently, researchers have investigated the reasons behind these failures
and revealed numerous failure factors, criticisms, impediments, and barriers that
jeopardise the success of LSS initiatives. These reasons, also recognised as LSS
limitations, represent the problem addressed in this research.
On the other hand, the Industry 4.0 (I4.0) era, entailing machine connectivity, big data
technologies and artificial intelligence, offers new opportunities for data-driven quality
improvement strategies such as LSS. Therefore, this study explored how I4.0
technologies can enhance the traditional LSS methodology by following a Design Science
Research (DSR) approach. The aim was to design a solution integrating I4.0 data-driven
tools into the traditional DMAIC framework to enhance the success and effectiveness of
LSS projects. DMAIC stands for Define, Measure, Analyse, Improve, and Control,
representing project phases executed in a prescribed order. The designed solution is a
DMAIC 4.0 framework that should help organisations overcome the limitations of LSS
by exploiting modern technologies and techniques.
This study adopts the DSR process described by Peffers et al. (2007), combined with
qualitative methods suggested by Offermann et al. (2009). There are three main phases:
(1) Problem Identification, (2) Solution Design and (3) Evaluation. Expert interviews
were conducted in phase 1 to confirm the problem and underpin its relevance. The design
built in phase 2 is based on existing knowledge and field experience. In phase 3, the
researcher successfully evaluated the framework’s utility and effectiveness within a
German manufacturing organisation through action research. Additionally, a Delphi
study demonstrated that the design presented is relevant and applicable to various
industries. Upon Delphi panel feedback, a roadmap was created to guide organisations in
implementing the new framework.
To the authors’ knowledge, this is the first DMAIC 4.0 framework presented in the
academic literature thus far. Knowledge and novel contributions were generated through the design and evaluation process. The validated framework includes 42 LSS tasks
enhanced by I4.0 technologies. It incorporates knowledge from extant research related to
LSS, DMAIC and I4.0. Furthermore, it focuses on tools and tasks and is more detailed
than previously presented frameworks integrating I4.0 with LSS. Unlike conceptual
frameworks, it is empirically validated, which should motivate LSS practitioners to
innovate their projects. Clearly, there is still room for expansion as there are many more
tools in both areas, LSS and I4.0. Researchers and practitioners can customise and apply
the framework in various contexts to establish a new standard for DMAIC