An Integrated Lean Six Sigma Framework for Waste Reduction and Resource Efficiency in Manufacturing

Abstract

Manufacturing industries face increasing challenges related to material waste, inefficient resource utilization, process variability, and rising operating costs. This study develops an integrated Lean Six Sigma framework for reducing waste and improving resource efficiency in manufacturing by combining Lean Manufacturing, Six Sigma, and data-driven process improvement techniques. The framework incorporates DMAIC, value stream mapping, 5S, Statistical Process Control (SPC), Pareto analysis, Failure Mode and Effects Analysis (FMEA), and root cause analysis. The reported evaluation indicates that defects decreased from 12% to 4.5%, cycle time decreased from 120 to 85 minutes, and process capability (Cpk) improved from 0.95 to 1.45. Estimated annual cost savings were approximately US$18,500, while customer satisfaction increased by 18%. These findings indicate that an integrated Lean Six Sigma approach can provide a structured basis for waste reduction, improved process performance, and more efficient resource utilization. The framework supports continuous improvement through systematic process analysis, data-driven decision-making, and performance monitoring.