Implementing Lean Six Sigma Methodologies in an Industry 4.0 Manufacturing Setup: A Case Study

Abstract

The integration of Lean Six Sigma (LSS) principles with Industry 4.0 technologies offers an effective way to improve operational performance in modern manufacturing environments. This case study presents the systematic application of LSS within an Industry 4.0 manufacturing laboratory, employing the DMAIC (Define, Measure, Analyze, Improve, Control) framework to identify and eliminate inefficiencies. In a context dominated by automation, cyber-physical systems, and data-driven decision making, the study addresses persistent challenges including inaccurate sensor readings, limited user knowledge of advanced systems, and suboptimal material storage configurations. Through a combination of statistical analysis, root-cause identification, and iterative process redesign, the intervention resulted in measurable improvements in process reliability, user experience, and overall workflow efficiency. The findings highlight how LSS can serve as an effective bridge between traditional continuous-improvement methodologies and digitalized manufacturing operations. Moreover, the outcomes position the integration of LSS as a foundational enabler for Industry 5.0, where human-centricity, resilience, and sustainability will increasingly shape manufacturing system design.

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Titel	Implementing Lean Six Sigma Methodologies in an Industry 4.0 Manufacturing Setup: A Case Study
Medien	Proceedings of the Conference on Production Systems and Logistics: CPSL
Verlag	Offenburg : publish-Ing.
Herausgeber	Herberger, D. , Hübner, M.
Band	2026
Verfasser	Shantall Marucia Cisneros Saldana, Prof. Dr. Heike Markus
Veröffentlichungsdatum	16.04.2026
Zitation	Cisneros Saldana, Shantall Marucia; Markus, Heike (2026): Implementing Lean Six Sigma Methodologies in an Industry 4.0 Manufacturing Setup: A Case Study. Proceedings of the Conference on Production Systems and Logistics: CPSL 2026.