DMAIC 4.0 - innovating the Lean Six Sigma methodology with Industry 4.0 technologies

This study employs Design Science Research to integrate I4.0 technologies into the DMAIC (Define, Measure, Analyse, Improve, Control) framework, resulting in the development and evaluation of a novel DMAIC 4.0 framework and a practical roadmap. The research journey unfolds in three phases: Problem Identification, Solution Design, and Evaluation. Initially, expert interviews revealed significant limitations in current LSS practices and highlighted opportunities to leverage modern technologies. The second phase focused on designing an innovative framework. The final phase involved rigorous evaluation through action research and a Delphi study, refining the framework into a practical implementation roadmap. The DMAIC 4.0 framework includes 42 DMAIC tasks enhanced by I4.0 technologies. As the first empirically validated DMAIC 4.0 framework in academic literature, it stands out for its novelty, comprehensiveness, and detailed approach. The validation process through action research and a Delphi study demonstrated its effectiveness and applicability across various industries. The integration of DMAIC and I4.0 provides a rich set of tools, paving the way for future research to expand and validate the framework or transform it into an audit tool for organizations to assess their degree of innovation.