Integrating Industry 4.0 tools into the Six Sigma DMAIC phases: a pathway to digital-driven quality improvement

Purpose The aim is to investigate the incorporation of Industry 4.0 (I4.0) technologies into the Six Sigma DMAIC (Define, Measure, Analyse, Improve, Control) framework. By focusing on enhancing process efficiency, quality management (QM), and operational performance, the study intended to offer a structured, phase-specific methodology. The objective is to present a detailed guide to systematically employing I4.0 tools, demonstrating their application across each stage of the DMAIC process to achieve improved outcomes. Design/methodology/approach The study employed a qualitative approach, conducting focus group discussions with Six Sigma and I4.0 experts from diverse industrial sectors. Thematic analysis was conducted to gain insights into the practical application of I4.0 technologies within the DMAIC framework. Additionally, a scoping review of existing literature was undertaken to identify gaps and opportunities, supporting the development of a comprehensive framework for integrating I4.0 tools into QM practices. Findings The findings indicate that I4.0 technologies significantly enhance the DMAIC phases by facilitating real-time data acquisition, advanced predictive analytics, and automated processes. Tools such as cloud-based platforms, IoT systems, and AI-driven analytical solutions contribute to greater precision and flexibility across all phases, from defining customer needs to maintaining control over process variations. These insights provide actionable guidance for integrating Industry 4.0 technologies into Six Sigma practices, resulting in improved outcomes and a sustained competitive advantage. Originality/value This research is one of the few studies to offer a detailed, phase-specific framework for incorporating I4.0 technologies into the Six Sigma DMAIC methodology. It enriches both theoretical understanding and practical applications in digital transformation within QM by addressing a significant gap in the existing literature. Its uniqueness stems from a comprehensive approach that merges empirical insights from industry professionals with a well-structured implementation guide tailored for practitioners.