Green Lean Six Sigma and Industry 4.0 integration for manufacturing sustainability: developing a design science research-based framework

Purpose This study aims to integrate Green Lean Six Sigma (GLSS) with Industry 4.0 (I4.0) and develop an integrated GLSS–I4.0 framework for manufacturing sustainability. Design/methodology/approach Implementing the GLSS–I4.0 strategy requires the cohesive integration of the GLSS approach with I4.0 technologies within a unified GLSS–I4.0 framework. In this study, the integration is proposed through intangible elements, such as enablers, barriers, tools and related frameworks. The Integrated GLSS–I4.0 model is based on the key aspects of each approach by Design Science Research and the Eight Disciplines (8D) problem-solving methodologies. The integrated framework has been developed by deploying various GLSS tools and I4.0 technologies together at the distinct phases of the project execution. The developed framework has been validated with the help of industrial experts. Findings Both approaches share common elements regarding critical success factors and barriers, and the combined application of their respective tools and techniques strengthens their shared objective of enhancing sustainability. The presented framework offers methodical guidelines from project selection to solution sustainment, outlining the application of various tools and techniques at each stage of the process. Practical implications This integration establishes a framework for researchers and practitioners to examine the complex interaction between sustainable quality management and advanced digital technologies. Moreover, this study enhances the discussion by highlighting the critical role of organizational culture in the digitalization process and the adoption of I4.0. Originality/value To the best of the authors’ knowledge, this is the first research for integrating GLSS with I4.0 technologies and developing an Integrated GLSS–I4.0 framework in the manufacturing environment by design science research methodology to enhance organizational sustainability.