Industry 4.0 and Lean Six Sigma Integration: A Systematic Review of Barriers and Enablers

Macias-Aguayo, Jaime; Garcia-Castro, Lizzi; Barcia, Kleber; McFarlane, Duncan

doi:10.3390/app122211321

Cited by 18 publications

(6 citation statements)

References 95 publications

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“…One of the key lean manufacturing tools closely related to the standardization of production processes is TPM. This tool allows you to achieve maximum efficiency with production equipment by involving many employees in the maintenance process [22,23]. In addition, it enables efficient and ongoing diagnostics of machines and production equipment, which requires monitoring of a number of parameters; it is very important from the point of view of the operation of machine and equipment elements and the continuity of production processes.…”

Section: Methodsmentioning

confidence: 99%

Digital Standardization of Lean Manufacturing Tools According to Industry 4.0 Concept

Medyński,

Bonarski,

Motyka

et al. 2023

Applied Sciences

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Standardization is a key element in the effective use of lean manufacturing methodologies and tools for achieving process sustainability. Their combination is conducive to eliminating waste and improving the efficiency of production processes and guarantees the company that employees use the most efficient tools and do not waste time on unnecessary activities. These activities can be further improved by using digital solutions, in accordance with the concept of Industry 4.0. Therefore, the authors have developed the e-Lean system, whose task is to digitize selected lean manufacturing tools. The subject of this work is analysis of the functionality and effectiveness of the essential part of the e-Lean system in the form of specialized TPM (Total Productive Maintenance) software as an application. During implementation in a construction production company, the TPM application was tested by lean manufacturing and maintenance specialists. The research consisted of assessing the functionality and efficiency of processes in relation to conventional TPM solutions. Additional functionalities of the e-Lean system have been confirmed, such as systemic approval of machinery inspection, which requires passing all necessary steps at individual inspection points, direct access for supervisors to the results of inspection activities and their status, direct and easy access to photographic documentation of machines added during inspection both in optimization of working time and its course (e.g., the optimal number of steps taken by the employee during the inspection), as well as an efficient system of motivating employees (collecting points). The improvement in the effectiveness of processes was determined by measuring the control times for three control points (polymerization furnace, packing area, and defibering machines). The average control time was reduced from 16,200 to 13,923 s. Thus, thanks to the use of the application, it was found that the efficiency of using the TPM tool was increased by approx. 15% compared to previously used non-digital solutions.

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Section: Methodsmentioning

confidence: 99%

Digital Standardization of Lean Manufacturing Tools According to Industry 4.0 Concept

Medyński,

Bonarski,

Motyka

et al. 2023

Applied Sciences

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“…The term sustainability or sustainable development refers to meeting the present generation's requirements without compromising the future generation's needs while ensuring a balance between economic growth, environmental protection and social well-being. Factors linked to the economic, social and environmental impacts of merging I4.0 and LSS remain unexplored from the perspective of sustainability and sustainable development (Buer et al, 2018;Macias-Aguayo et al, 2022). According to Yilmaz et al (2022), there are only limited number of studies in the integration of LSS and I4.0 that focus on the environmental and social dimensions of sustainability.…”

Section: Need For the Studymentioning

confidence: 99%

“…Factors linked to the economic, social and environmental impacts of merging I4.0 and LSS remain unexplored from the perspective of sustainability and sustainable development (Buer et al. , 2018; Macias-Aguayo et al. , 2022).…”

Section: Introductionmentioning

confidence: 99%

Lean Six Sigma and Industry 4.0 – a bibliometric analysis and conceptual framework development for future research agenda

Citybabu

Yamini

2023

IJPPM

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PurposeThe purpose of this paper is to investigate the research landscape of LSS 4.0 papers published in two well-known repositories, Scopus and Web of Science (WoS), in terms of publication trends, article distribution by author, journal, affiliations and country, and article clustering based on keywords, authors and countries. In addition, a literature review was carried out to build a conceptual framework of integrated Lean Six Sigma and Industry 4.0 (LSS 4.0) that encompasses operational, sustainability and human factors or ergonomics aspects.Design/methodology/approachThe literature review of integrated Lean Six Sigma and I4.0 publications published in Scopus and WoS databases in the current decade was conducted for the present study. This study categorizes LSS, I4.0 and related research articles based on publication patterns, journals, authors and affiliations, country and continental-wise distribution and clustering the articles based on keywords and authors from the Scopus and WoS databases from 2011 to 2022 using the search strings “Lean”, “Six Sigma”, “Lean Six Sigma” and “Industry 4.0” in the Title, Abstract and Keywords using Biblioshiny, VOS viewer and Microsoft Excel.FindingsIn the recent three years, from 2020 to 2022, LSS 4.0 has been substantially increasing and is seen as an emerging and trending area. This research identifies the most influential authors, most relevant affiliations, most prolific countries and most productive journals and clusters based on keywords, authors and countries. Further, a conceptual framework was developed that includes the impact of operational, sustainability and ergonomic or human factors in LSS 4.0.Research limitations/implicationsThis article assists in comprehending the trends and patterns of LSS 4.0. Further, the conceptual framework helps professionals and researchers understand the significance and impact of integrating LSS and Industry 4.0 in the aspects of human factors/ergonomic, sustainability and operations. Also, the research induce professionals to incorporate all these factors while designing and implementing LSS 4.0 in their organization.Originality/valueThis conceptual framework and bibliometric analysis would aid in identifying potential areas of research and providing future directions in the domain of LSS 4.0. It will be beneficial for academicians, professionals and researchers who are planning to apply and integrate techniques of LSS and technologies of I4.0 in their organizations and research.

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“…Additional barriers identified included the lack of management involvement [197], cultural barriers, resource limitations [198], physicians' resistance to change [199][200][201], implementation cost, long learning curve, and technology incompatibility [202]; all of them are worth considering in future interventions.…”

Section: Barriers and Challengesmentioning

confidence: 99%

Lean, Six Sigma, and Simulation: Evidence from Healthcare Interventions

et al. 2022

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In the Industry 4.0 era, healthcare services have experienced more dual interventions that integrate lean and six sigma with simulation modeling. This systematic review, which focuses on evidence-based practice and complies with the PRISMA guidelines, aims to evaluate the effects of these dual interventions on healthcare services and provide insights into which paradigms and tools produce the best results. Our review identified 4018 studies, of which 39 studies met the inclusion criteria and were selected. The predominantly positive results reported in 73 outcomes were mostly related to patient flow: length of stay, waiting time, and turnaround time. In contrast, there is little reported evidence of the impact on patient health and satisfaction, staff wellbeing, resource use, and savings. Discrete event simulation stands out in 74% of the interventions as the main simulation paradigm. Meanwhile, 66% of the interventions utilized lean, followed by lean-six sigma with 28%. Our findings confirm that dual interventions focus mainly on utilization and access to healthcare services, particularly on either patient flow problems or problems concerning the allocation of resources; however, most interventions lack evidence of implementation. Therefore, this study promotes further research and encourages practical applications including the use of Industry 4.0 technologies.

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Industry 4.0 and Lean Six Sigma Integration: A Systematic Review of Barriers and Enablers

Cited by 18 publications

References 95 publications

Digital Standardization of Lean Manufacturing Tools According to Industry 4.0 Concept

Digital Standardization of Lean Manufacturing Tools According to Industry 4.0 Concept

Lean Six Sigma and Industry 4.0 – a bibliometric analysis and conceptual framework development for future research agenda

Lean, Six Sigma, and Simulation: Evidence from Healthcare Interventions

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