A framework for integrating Lean Six Sigma and Industry 4.0 for sustainable manufacturing
提出一个基于DMAIC的整合框架，将精益六西格玛与工业4.0技术结合，通过案例验证可显著降低缺陷率（如裂纹缺陷减少75%），帮助制造企业提升效率与可持续性。
This study presents a DMAIC-based integrated framework combining Lean Six Sigma and Industry 4.0 to achieve sustainable manufacturing. The framework systematically combines Lean Six Sigma's principles of waste reduction and process optimisation with Industry 4.0 technologies. The study identified and prioritised critical enablers and barriers for the effective implementation of the framework using the Analytic Hierarchy Process (AHP). Results revealed that management commitment, employee engagement, and technology infrastructure emerged as the highest-ranked enablers and high initial costs, lack of skilled workforce and resistance to change were identified as the most critical barriers. Additionally, key readiness dimensions such as technological, organisational, human factors and process readiness were also evaluated. The proposed framework’s effectiveness is validated through a welding-based case study, where an automated computer vision was employed to reduce the defects in real-time. The results indicated a significant improvement in product quality, operational efficiency and sustainability, achieved through continuous real-time monitoring and corrective actions. Defect rates were substantially reduced, including a 75% decrease in crack defects and 67% reduction in porosity, supporting the framework’s capability to enhance zero-defect manufacturing. This study provides a structured roadmap for practitioners and can be adapted to manufacturing sectors aiming to enhance both efficiency and sustainability.