An assessment of barriers to integrate lean six sigma and industry 4.0 in manufacturing environment: case based approach

The integration of Lean Six Sigma (LSS) with Industry 4.0 (I4.0) has numerous advantages for the organization. LSS and I4.0 integration in manufacturing environments face some challenges, including data integration, a lack of understanding of the strategic implications of integrating LSS and I4.0, security and data privacy issues, return on investment, and a shortage of consultants and trainers. This paper aims to analyse the barriers and their interrelationship that could hinder the manufacturing organisation from embracing LSS with I4.0. Fifteen potential barriers were identified from the literature review and by taking the opinion of experts and decision-makers. The grey decision-making trial and evaluation laboratory (DEMATEL) method was applied to find the influence of each barrier on other barriers. The cause–effect relationship between the barriers was identified and later validated by experts. Using a single case study methodology, this study prioritises the identified barriers that hinder the automotive component manufacturing industry from integrating LSS with I4.0. The top three barriers were ‘lack of long-term vision’, ‘timely and accurate data availability’, and ‘lack of automation’. This paper will help the managers to better understand which barriers could affect the integration of LSS with I4.0.