Integrating Six Sigma into an Industry 4.0 System for Enhanced Productivity: A Case Study in CNC Processes

Nowaday, many manufacturing companies are integrating Industry 4.0 technology into their operational processes, particularly those aiming to enhance production operations. However, business decision-makers must remain vigilant about potential risks associated with adopting this technology. These risks include initial financial investments for testing and system installation, managing human resources to operate the new system, and concerns regarding data security. This study proposes designing an Industry 4.0 technology system to augment machining machine operations, leveraging Internet of Things (IoT) devices to facilitate connectivity and data transmission. Additionally, it aims to improve production process monitoring through visual management techniques. The machines under study are semi-automatic and lack operational digitization or expansion capacity. Through research on integrating low-cost Industry 4.0 technology into the production process, this study has achieved an annual reduction in production costs by $9593. Moreover, the defect rate for product length dimensions has plummeted from 54.90% per month to zero defects. The study employs the DMAIC method (Define-Measure-Analysis-Improve-Control) cycle within the Six Sigma methodology to investigate and apply low-cost Industry 4.0 technology to production process enhancement. This combined approach can be customized and applied to various business process improvement models, further enhancing the operation of machining machines originally equipped with Industry 3.0 technology.