When Industry 4.0 meets Lean Six Sigma: A review

Sodhi, Harsimran Singh

doi:10.26488/iej.13.1.1214

Cited by 28 publications

(18 citation statements)

References 35 publications

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“…(Kim and Ree, 2017). Research on LSS competitiveness within I4.0 is in its infancy stage (Sodhi, 2020). Research in the direction of simulation, optimization, and modelling of the data, which are the basic tenets of both I4.0 and LSS, will cause a leap in profitability to the industry (Antony et al , 2018; Gupta et al , 2020).…”

Section: Introductionmentioning

confidence: 99%

Simulation-based lean six sigma for Industry 4.0: an action research in the process industry

Bhat

Bhat²,

Gijo

2020

IJQRM

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PurposeThe primary aim of this article is to ascertain the modalities of leveraging Lean Six Sigma (LSS) for Industry 4.0 (I4.0) with special reference to the process industries. Moreover, it intends to determine the applicability of simulation-based LSS in the automation of the mineral water industry, with special emphasis on the robust design of the control system to improve productivity and performance.Design/methodology/approachThis study adopts the action research methodology, which is exploratory in nature along with the DMAIC (define-measure-analyze-improve-control) approach to systematically unearth the root causes and to develop robust solutions. The MATLAB simulation software and Minitab statistical software are effectively utilized to draw the inferences.FindingsThe root causes of critical to quality characteristic (CTQ) and variation in purity level of water are addressed through the simulation-based LSS approach. All the process parameters and noise parameters of the reverse osmosis (RO) process are optimized to reduce the errors and to improve the purity of the water. The project shows substantial improvement in the sigma rating from 1.14 to 3.88 due to data-based analysis and actions in the process. Eventually, this assists the management to realize an annual saving of 20% of its production and overhead costs. This study indicates that LSS can be applicable even in the advent of I4.0 by reinforcing the existing approach and embracing data analysis through simulation.Research limitations/implicationsThe limitation of this research is that the inference is drawn based on a single case study confined to process industry automation. Having said that, the methodology deployed, scientific information related to optimization, and technical base established can be generalized.Originality/valueThis article is the first of its kind in establishing the integration of simulation, LSS, and I4.0 with special reference to automation in the process industry. It also delineates the case study in a phase-wise manner to explore the applicability and relevance of LSS with I4.0. The study is archetype in enabling LSS to a new era, and can act as a benchmark document for academicians, researchers, and practitioners for further research and development.

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Section: Introductionmentioning

confidence: 99%

Simulation-based lean six sigma for Industry 4.0: an action research in the process industry

Bhat

Bhat²,

Gijo

2020

IJQRM

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“…Synergy of Lean Manufacturing and six sigma aim to reach the quality levels of 3.4 parts per million defects by reducing the variations in processes. Industry 4.0 is tending toward the digitalization of manufacturing activities with powerful data analysis methods that can drive meaningful results out of the big data available [19].…”

Section: Methodsmentioning

confidence: 99%

Adaptation of the Lean 6S Methodology in an Industrial Environment under Sustainability and Industry 4.0 Criteria

et al. 2021

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Industry 4.0 paradigms have a positive influence on standard operating procedures, methodologies used in Lean Manufacturing techniques and management models with sustainability criteria. Interdependencies and correlations have been found between Lean systems and Industry 4.0. The Lean principles of avoiding waste and zero defects are related to the cloud and big data paradigms. In a current workplace, there has been an exponential increase in digital information and the need to generate direct commitments to environmental management. This situation forces us to innovate and improve the management methodologies and models used in the industrial environment. The Lean 6S methodology must adapt and respond to new demands. In this work, an update of the Lean 6S methodology is carried out to guarantee increased productivity in the workplace through the organization of industrial resources, both physical and digital. A revision of the implementation procedure is proposed, which includes activities that generate a direct commitment to sustainability and the organization of digital information, through a proposal for an organizational architecture of Industry 4.0 technologies.

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“…The challenge in the future is the implementation of six Sigma in industries and businesses to utilize the Industry 4.0 concept [53], [54], [55] or even with minor changes by poka-yoke or fault-proof [56]. Table 3 also shows the criteria in Industry 4.0 which will enhance and enabler the Six Sigma implementation.…”

Section: Research Gap and Industry 40 Concept For Six Sigma Enhancementmentioning

confidence: 99%

“…Industry 4.0 concept to enhance six sigma implementation [53], [54], [55]. In the example of early product design and equipment management, digitalization can remove the boundaries between the planning and design phases on the one hand and the production phases on the other [55]. Another benefit of digitalization is a shorter product lifecycle, a wider variety of products, and increased product complexity, which will provide a platform for an increase in production rates.…”

Section: Research Gap and Industry 40 Concept For Six Sigma Enhancementmentioning

confidence: 99%

Six Sigma Implementation in Indonesia Industries and Businesses: A Systematic Literature Review

Widjajanto

Purba

2021

JEMIS

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Understanding quality in manufacturing starts with defect identification and improvement finding. Reliability that influenced by equipment design or working methods or environment has led to concept of improvement with six sigma method and this has been absorbed in Indonesia industries as well. This article discusses about six sigma implementation in Indonesia from various business and industries. The method is to review research articles that are published within 2016-2020 with keyword DMAIC and six sigma. The results from 52 selected articles is obtained average 3.68 sigma value of Indonesia industries within year 2016-2020 with the least value 1.10 from crude palm oil refinery and the highest is 5.10 from bagging process of sugar refinery. However, six sigma application is not always satisfying concerning its suitability function, requirement of industries, culture, local regulation, and internal business concern, especially in terms of efficiency and cost. Future research is suggested utilizing industry 4.0 concept to enhance six sigma implementations.

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When Industry 4.0 meets Lean Six Sigma: A review

Cited by 28 publications

References 35 publications

Simulation-based lean six sigma for Industry 4.0: an action research in the process industry

Simulation-based lean six sigma for Industry 4.0: an action research in the process industry

Adaptation of the Lean 6S Methodology in an Industrial Environment under Sustainability and Industry 4.0 Criteria

Six Sigma Implementation in Indonesia Industries and Businesses: A Systematic Literature Review

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