Lean Six Sigma 4.0 in an empirical application: a case of digital measurement for thickness deviation on a galvanizing line in a steel industry

Purpose This study aims to explore an empirical investigation for developing a digital control system for identifying steel sheet thickness deviation to improve productivity and coating quality on a galvanizing process line in the context of Lean Six Sigma 4.0. Design/methodology/approach This paper used a Lean Six Sigma 4.0 empirical application approach to promote a digital control system in zinc thickness measurement. The approach covered equipment specification, network configuration, control and monitoring software, security routine, thickness calculation, deviation routine and supervisory system. Performance tests show that this approach has produced good results, making it a viable application. Findings The main contribution of this study is to demonstrate that Lean Six Sigma 4.0 concepts can promote the measurement of steel sheet thickness deviations with accuracy, sensitivity and reliability, as demanded by the global market. The results of this study showed errors of 0.1% of the actual thickness, making it technically feasible to implement this system for steel sheet thickness readings ranging from 0.01 mm to 4 mm. Originality/value This research demonstrates an interdimensional linkage between Lean Six Sigma 4.0 concepts to explore an empirical investigation for implementing a digital control system using data acquisition modules and control software to guarantee the coating quality applied to steel products under the standard organization.