A Lean–Six Sigma–Ergonomics Index for Assessing Shop-Floor Operational Resilience Readiness: Method Development and SME Demonstration

Operational resilience readiness at the shop-floor level depends on efficient process flow, stable quality, and adequate human–system capacity, yet these dimensions are commonly assessed separately. This article presents the Lean–Six Sigma–Ergonomics Operational Resilience Index (LSE–ORI), a non-interventional composite method for assessing manufacturing conditions that support resilience readiness. Process-flow efficiency is represented by Process Cycle Efficiency, quality stability by the actual sigma level normalized against a defined target, and human–system capacity by physical, cognitive, and macroergonomic assessments. The scores are standardized to a 0–1 scale and combined multiplicatively to produce the index and identify the lowest-scoring dimension. A two-month demonstration involving 13 operators on a tractor spare-parts production line yielded scores of 0.60, 0.54, and 0.62, resulting in an ORI of approximately 0.20. Quality stability was the lowest-scoring primary component, while work-system structural support was the weakest subcomponent within the human–system. Content validation by 15 experts across 64 items produced a minimum I-CVI of 0.933 and an S-CVI/Ave of 0.995, supporting applicability, calculation traceability, and content validity. Main advantages of the proposed method: • Integrates three shop-floor dimensions into one assessment. • Uses operational data without changing the production system. Provides hierarchical diagnosis of the lowest-scoring component.