Improving the economic and environmental sustainability of painting and glueing operations in a luxury leather goods industry using DMAIC methodology – a case study

Abstract The luxury personal goods industry is facing increasing pressure to improve economic and environmental sustainability in its production processes. Thus, efforts need to be made to improve some of the traditional operations performed in this sector. In fact, a gap is found in studies intending to enhance the operational efficiency of this sector. Thus, this study seeks to improve painting and glueing operations in this sector using the DMAIC (Define, Measure, Analyze, Improve, Control) methodology. The research was focused on analyzing existing practices, identifying inefficiencies, and implementing targeted improvements. Key findings show that restructuring filter management enabled a reduction of 258.07 kg of waste sent to landfill after two weeks of implementation, resulting in weekly savings of €112.19 and 88.72% reduction in disposal costs. In addition, standardizing filter types across different equipment improved operational efficiency, reduced inventory discrepancies and became a large area in the warehouse. The results highlight the effectiveness of integrating Lean and Six Sigma methodologies in optimizing production in the sector. The study concludes that systematic improvements generate substantial economic benefits and reduce the environmental footprint. This case study serves as a reference for similar industries seeking sustainable practices without compromising production quality and competitiveness. The research reinforces the importance of continuous improvement to achieve sustainability goals in manufacturing.