PurposeThe purpose of the present work is identification and prioritization of barriers to Lean Six Sigma (LSS) implementation in Indian manufacturing industries in the context of Industry 4.0 (I4.0) to surmount the impediments in the path of successful implementation.Design/methodology/approachIn total, 27 barriers identified through critical review of literature and expert's opinion are evaluated with Cronbach's alpha values including item-total correlations or corrected item-total correlations (CITC) using statistical tool. Finally, 20 barriers were analyzed and ranked employing Fuzzy Analytical Hierarchy Process (FAHP).FindingsThe study depicts that “Lack of leadership, advisory and monitoring,” “Lack of clarity about economic benefits” and “Lack of integration of LSS with smart tools/I4.0” are potential barriers to drive the path for proper implementation of LSS in Industry 4.0 with due consideration of its technologies in Indian manufacturing industries.Practical implicationsThe study provides better knowledge platform for academicians and researchers about hidden aspects of LSS implementation barriers in view of advanced manufacturing technologies. This research will help the practitioners to design their business plans in implementing new quality improvement tools to get advantage in current competitive environment.Originality/valueThe barriers are selected based on literature and opinion from industry and academic experts. Five major criteria are decided after incorporating inputs. The ranking of the barriers is attained by well standard mathematical technique. This will enable the practitioners to design strategies to eliminate the hindrances in order to shape the right path for effective implementation of LSS approach in view of advanced manufacturing technologies.

The present study is application of taguchi method to optimize the process parameters of injection molding machine to minimize the shrinkage of product to enhance the quality of product. The predicted optimal setting ensures minimum shrinkage of product. Five process parameters of plastic injection molding machine were taken as melt temperature, mold temperature, injection pressure, holding pressure and cooling time. By ANOVA analysis it is found that melt temperature is most significant and cooling time is least significant factor affecting the dimensional shrinkage of manufactured plastic product.