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Lean Six Sigma with Value Stream Mapping in Industry 4.0 for Human-Centered Workstation Design

Author

Listed:
  • Fu-Kwun Wang

    (Department of Industrial Management, National Taiwan University of Science and Technology, Taipei City 106335, Taiwan)

  • Benedictus Rahardjo

    (Department of Industrial Management, National Taiwan University of Science and Technology, Taipei City 106335, Taiwan)

  • Pol Rifa Rovira

    (Thermo King Ireland Limited, D02 Dh60 Dublin, Ireland)

Abstract

Many industries have successfully implemented the define-measure-analyze-improve-control (DMAIC) method of Lean Six Sigma to improve their production activities. Value stream mapping (VSM) for Industry 4.0 allows us to understand the current state of operations in order to plan future improvements. In this study, we propose an improvement model based on DMAIC with VSM 4.0 for a truck cooler manufacturer to improve the picking workstation design with a human-centered approach. We use the DMAIC method to analyze the project step by step. After identifying the root cause, we identified countermeasures to improve the productivity. To reduce human error, the project team adopted a human-centered approach and applied lean tools, such as visual management, error prevention, and waste analysis. As a result of this case study, the yield rate was improved from 98% to 100%, and the direct savings of the project amounted to EUR 3180, mainly due to the freeing up of space. A human-centered LSS framework is also presented as a novel contribution of this study.

Suggested Citation

  • Fu-Kwun Wang & Benedictus Rahardjo & Pol Rifa Rovira, 2022. "Lean Six Sigma with Value Stream Mapping in Industry 4.0 for Human-Centered Workstation Design," Sustainability, MDPI, vol. 14(17), pages 1-19, September.
    • Handle: RePEc:gam:jsusta:v:14:y:2022:i:17:p:11020-:d:906074
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    References listed on IDEAS

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    1. Carla M. A. Pinto & Jorge Mendonça & Lurdes Babo & Francisco J. G. Silva & José L. R. Fernandes, 2022. "Analyzing the Implementation of Lean Methodologies and Practices in the Portuguese Industry: A Survey," Sustainability, MDPI, vol. 14(3), pages 1-24, February.
    2. Naga Vamsi Krishna Jasti & Rambabu Kodali, 2015. "Lean production: literature review and trends," International Journal of Production Research, Taylor & Francis Journals, vol. 53(3), pages 867-885, February.
    3. Lea Hannola & Alexander Richter & Shahper Richter & Alexander Stocker, 2018. "Empowering production workers with digitally facilitated knowledge processes – a conceptual framework," International Journal of Production Research, Taylor & Francis Journals, vol. 56(14), pages 4729-4743, July.
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    Cited by:

    1. Pedro Marques & Lígia Conceição & André M. Carvalho & João Reis, 2025. "Driving Sustainable Operations: Aligning Lean Six Sigma Practices with Sustainability Goals," Sustainability, MDPI, vol. 17(19), pages 1-23, October.

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