Lean Six Sigma and Industry 4.0 implementation framework for operational excellence: a case study

The adoption of Lean Six Sigma (LSS) 4.0 has been recommended by researchers and practitioners as an effective strategy to enhance the operational excellence of companies, especially in highly competitive environments given the complementarity of LSS with Industry 4.0 (I4.0). Moreover, evidence suggests that companies commonly face difficulties and perceive the implementation process as challenging. To the best of our knowledge, there is currently no comprehensive global model available that offers a step-by-step approach for implementing LSS4.0. The purpose of this study is, therefore, to develop a structured framework that directs organizations to successfully implement LSS4.0. This study follows a combined approach including a systematic literature review to identify existing gaps in recent research and an expert panel to provide valuable insights and validation during the development of the framework. Additionally, a case study was conducted in an automotive manufacturing company to validate the findings. The proposed LSS4.0 framework is based on the DMAIC approach subdivided into fifteen steps. It permits managers to seamlessly integrate LSS4.0 into their processes and selectively choose the relevant tools as required, avoiding digitalization without a clear purpose. Also, it offers a comprehensive solution for managers addressing contemporary industry challenges and enhancing operational processes.