Quality System Improvement Using Sustainable Lean Manufacturing and Six Sigma in the Heavy Components Industry

This study applied quality system improvement using sustainable lean manufacturing and the six-sigma approach in the heavy component industry using the plan–do–check–action (PDCA) cycle. This study aimed to constitute the application quality system improvement as the integration of statistical process control, lean manufacturing, Six Sigma, sustainable awareness, and Quality 4.0 in the heavy component manufacturing industry. Improvement strategies were implemented using tools such as Sustainable Value Stream Mapping (SVSM), manufacturing, Process Activity Mapping (PAM), and decision tree CART classification analysis. Key improvements included the implementation of jig redesign, use of QR code scanners, making a finishing table in the production process, regular cleaning of welding tools, and visualization of data with the Power Business Intelligence dashboard. Post-intervention analysis demonstrated an improved sigma level of 3,748 from 3,361. PCE increased from 82.71% to 83.72%. The results of the indicator values. The average sustainability category is in the yellow traffic light condition, namely 61%–90%, which means that this indicator can still be improved to achieve the company’s targets. After implementing this concept, the company can produce more efficient processes. The proposed quality system improvement model significantly enhances process quality and operational sustainability in the heavy component industry.

Lean manufacturing; Quality 4.0; Quality system; Six Sigma; Sustainable

Amrina, U., & Zagloel, T. Y. M. (2019). The harmonious strategy of lean and green production: Future opportunities to achieve sustainable productivity and quality. IEEE 6th International Conference on Industrial Engineering and Applications (ICIEA). https://doi.org/10.1109/ICIEA47049.2019

Arons, A., Tsevat, R. K., Hotez, E., Huang, H., Nott, R., Ahn, H. H., Mehta, N., Nguyen, L., Nguyen, V., Rebollar, A. G., Duan, S., & Ma, J. (2024). A quality improvement initiative to improve health care transition planning at adolescent well visits. Academic Pediatrics, 24(6), 973–981. https://doi.org/10.1016/j.acap.2024.03.013

Bagherian, A., Gershon, M., Kumar, S., & Mishra, M. K. (2024). Analyzing the relationship between digitalization and energy sustainability: A comprehensive ISM-MICMAC and DEMATEL approach. Expert Systems with Applications, 236, 121193. https://doi.org/10.1016/j.eswa.2023.121193 

Bao, W. J., Wang, C., Zhang, L. L., & Yu, H. X. (2024). Impact of combined cluster nursing and Plan-Do-Check-Act cycle on postoperative infection risk and clinical outcomes in patients with open fractures and multidrug resistance. Asian Journal of Surgery, 47(10), 4613–4614. https://doi.org/10.1016/j.asjsur.2024.07.287

Benabdellah, A. C., Zekhnini, K., Cherrafi, A., & Reyes, J. G. (2024). Driving sustainable innovation: Exploring lean, green, circular, and smart design. Procedia Computer Science, 232, 880–889. https://doi.org/10.1016/j.procs.2024.01.088

Budhijanto, B., Bima, P. P., & Danang, T. H. (2024). Enhancing the quality of cassava starch-based wood bioadhesive using polyvinyl alcohol. International Journal of Technology, 15(6), 1886–1897. https://doi.org/10.14716/ijtech.v15i6.5789

Delgadillo, R. R., Medini, K., & Wuest, T. (2022). A DMAIC framework to improve quality and sustainability in additive manufacturing—A case study. Sustainability, 14(1), 1–18. https://doi.org/10.3390/su14010581

Dey, P. K., Malesios, C., De, D., Chowdhury, S., & Abdelaziz, F. B. (2019). The impact of lean management practices and sustainably oriented innovation on sustainability performance of small and medium-sized enterprises: Empirical evidence from the UK. British Journal of Management, 31(1), 141–161. https://doi.org/10.1111/1467-8551.12388

Elnadi, M., Gheith, M. H., Troise, C., Bresciani, S., & Abdallah, Y. O. (2025). Examining the interplay of Industry 4.0, lean, agile, and circular manufacturing practices on sustainability performance. Technovation, 146, 103290. https://doi.org/10.1016/j.technovation.2025.103290 

Erdil, N. O., Aktas, C. B., & Arani, O. M. (2018). Embedding sustainability in lean six sigma efforts. Journal of Cleaner Production, 198, 520–529. https://doi.org/10.1016/j.jclepro.2018.07.048

Fatemi, S., & Franchetti, M. J. (2016). An application of sustainable lean and green strategy with a Six Sigma approach on a manufacturing system. International Journal of Six Sigma and Competitive Advantage, 10(1), e08053. https://doi.org/10.1504/ijssca.2016.080453

Fitriana, R., Saragih, J., & Fauziyah, S. D. (2020). Quality improvement on common rail type-1 product using Six Sigma method and data mining on forging line in PT. ABC. IOP Conference Series: Materials Science and Engineering, 847, 012038. https://doi.org/10.1088/1757-899X/847/1/012038 

Fitriana, R., Saragih, J., & Larasati, D. P. (2020). Production quality improvement of Yamalube bottle with Six Sigma, FMEA, and data mining in PT. B. IOP Conference Series: Materials Science and Engineering, 847, 012011. https://doi.org/10.1088/1757-899X/847/1/012011 

Fitriana, R., Sari, D. K., & Habyba, A. N. (2021). Pengendalian dan penjaminan mutu. Wawasan Ilmu.

Garbie, I. (2016). Sustainability in manufacturing enterprises: Concepts, analyses and assessments for Industry 4.0. Springer Nature. https://doi.org/10.1007/978-3-319-29306-6

Gholami, H., Jamil, N., Saman, M. Z. M., Streimikiene, D., Sharif, S., & Zakuan, N. (2021). The application of green lean Six Sigma. Business Strategy and the Environment, 30(4), 1913–1931. https://doi.org/10.1002/bse.2724

Ginting, R., Napitupulu, H., Ishak, A., & Supranata. (2025). Bitewing holder and support product design using quality function deployment. International Journal of Technology, 16(2), 551–560. https://doi.org/10.14716/ijtech.v15i6.5789

Ginting, R., Silalahi, R., & Marunduri, M. A. (2025). The conceptual integration of quality function deployment and value engineering for product development: A case study of water dispenser. International Journal of Technology, 16(1), 124–135. https://doi.org/10.14716/ijtech.v16i1.6326 

Guleria, P., Pathania, A., Bhatti, H., Rojhe, K., & Mahto, D. (2021). Leveraging lean Six Sigma: Reducing defects and rejections in filter manufacturing industry. Materials Today: Proceedings, 46, 8532–8539. https://doi.org/10.1016/j.matpr.2021.03.535

Hartini, S., Manurung, J., & Rumita, R. (2021). Sustainable-value stream mapping to improve manufacturing sustainability performance: Case study in a natural dye batik SME’s. IOP Conference Series: Materials Science and Engineering, 1072(1), 012066. https://doi.org/10.1088/1757-899X/1072/1/012066 

Hussain, K., He, Z., Ahmad, N., Iqbal, M., & Mumtaz, S. M. T. (2019). Green, lean, Six Sigma barriers at a glance: A case from the construction sector of Pakistan. Building and Environment, 161, 106225. https://doi.org/10.1016/j.buildenv.2019.106225

Khodeir, L. M., & Othman, R. (2016). Examining the interaction between lean and sustainability principles in the management process of AEC industry. Ain Shams Engineering Journal, 9, 1627–1634. https://doi.org/10.1016/j.asej.2016.12.005

Lestari, L., Marie, I. A., & Sari, E. (2021). Sustainable Lean Six Sigma competitive manufacturing strategy for luggage manufacturer. Journal of Modern Manufacturing System Technology, 5(2), 22–34. https://doi.org/10.15282/jmmst.v5i2.6849

Lubaba, M., Hosen, M. I., Shakur, M. S., & Rahman, M. A. (2025). An intuitionistic fuzzy approach to assessing the barriers to Quality 4.0 adoption in the footwear manufacturing industry: Implications for sustainability in emerging economy. Journal of Open Innovation: Technology, Market, and Complexity, 11(3), 1–19. https://doi.org/10.1016/j.joitmc.2025.100604 

Mahdzir, M., Yahaya, S., Fauadi, M., & Yeow, T. (2024). Integrating water quality model and aeration with IoT technology in water quality management: A conceptual framework. Multidisciplinary Science Journal, 7, 2025139. https://doi.org/10.31893/multiscience.2025139 

Marie, I. A., Sari, E., & Lika, C. A. (2020). Enhancing sustainable maintenance performance using lean competitive manufacturing strategy: A case study in steel company. Solid State Technology, 63(6), 943–948. https://doi.org/10.1145/3557738.3557845

Montella, E., Di Cicco, M. V., Ferraro, A., Centobelli, P., Raiola, E., Triassi, M., & Improta, G. (2016). The application of Lean Six Sigma methodology to reduce the risk of healthcare-associated infections in surgery departments. Journal of Evaluation in Clinical Practice, 23(4), 530–539. https://doi.org/10.1111/jep.12662

Montgomery, D. C. (2013). Statistical quality control (7th ed.). John Wiley & Sons.

Rahardjo, B., Wang, F. K., Lo, S. C., & Chu, T. H. (2023). A sustainable innovation framework based on Lean Six Sigma and Industry 5.0. Arabian Journal for Science and Engineering, 49, 7625–7642. https://doi.org/10.1007/s13369-023-08565-3

Ramadhani, R. A., Fitriana, R., & Habyba, A. N. (2023). Enhancing quality control of packaging product: A Six Sigma and data mining approach. Jurnal Optimasi Sistem Industri, 22(2), 197–214. https://doi.org/10.25077/josi.v22.n2.p197-214.2023

Rathi, R., Kaswan, M. S., Garza-Reyes, J. A., Antony, J., & Cross, J. (2022). Green Lean Six Sigma for improving manufacturing sustainability: Framework development and validation. Journal of Cleaner Production, 345, 131130. https://doi.org/10.1016/j.jclepro.2022.131130 

Reddy, A., Nagpal, D., & Saxena, S. (2024). A Six Sigma approach to pharmaceutical industry: A better insight. Oriental Journal of Chemistry, 40, 1415–1425. https://doi.org/10.13005/ojc/400525 

Ruben, R. B., Vinodh, S., & Asokan, P. (2017a). Implementation of Lean Six Sigma framework with environmental considerations in an Indian automotive component manufacturing firm: A case study. Production Planning & Control, 28(9), 1193–1211. https://doi.org/10.1080/09537287.2017.1357215 

Ruben, R. B., Vinodh, S., & Asokan, P. (2017b). Lean Six Sigma with environmental focus: Review and framework. International Journal of Advanced Manufacturing Technology, 94, 4023–4037. https://doi.org/10.1007/s00170-017-1148-6

Sari, E., Ma’aram, A., Shaharoun, A. M., Chofreh, A. G., Goni, F. A., Klemeš, J. J., Marie, I. A., & Saraswati, D. (2021). Measuring sustainable cleaner maintenance hierarchical contributions of the car manufacturing industry. Journal of Cleaner Production, 312, 127717. https://doi.org/10.1016/j.jclepro.2021.127717

Sucipto, B. A., Syahputri, A. R., Mulyarto, A. R., & Tolle, H. (2025). Building transparency through halal and quality traceability system for beef distribution in Malang City, Indonesia. International Journal of Technology, 16(4), 1253–1264. https://doi.org/10.14716/ijtech.v16i4.5984 

Tamher, S. D., Rachmawaty, R., & Erika, K. A. (2021). The effectiveness of Plan–Do–Check–Act (PDCA) method implementation in improving nursing care quality: A systematic review. Enfermería Clínica, 31(5), S627–S631. https://doi.org/10.1016/j.enfcli.2021.07.006

Zhang, M., Zhao, S., & Xu, G. (2024). Plan–Do–Check–Act was applied to improve the first success rate of radial artery catheterization in anesthesiology residents. Asian Journal of Surgery, 48(2), 1380–1381. https://doi.org/10.1016/j.asjsur.2024.08.173