Mapping the landscape of critical failure factors in Lean Six Sigma 4.0 implementation: an ISM–DEMATEL approach

Purpose Lean Six Sigma 4.0 (LSS 4.0) transforms business operations by integrating Lean Six Sigma (LSS) with Industry 4.0 (I4.0), thereby enhancing operational excellence, resilience, sustainability and human factors such as ergonomics and hedonomics. Both developed and developing countries are actively embracing LSS 4.0. However, several critical failure factors (CFFs) of LSS 4.0 have the potential to impede its successful implementation. This study aims to identify and analyze the intricate interplay among these CFFs in the context of LSS 4.0 adoption. Design/methodology/approach An extensive literature review identified around 35 failure factors related to LSS and I4.0. A survey among experts, conducted using a survey form, revealed 15 CFFs that impact the success of LSS 4.0. To assess these critical factors, an integrated approach involving interpretive structural modeling (ISM), cross-impact matrix multiplication applied to classification (MICMAC) and decision-making trial and evaluation laboratory (DEMATEL) was applied. This sheds light on the intricate relationships among these factors and their influence on LSS 4.0. Findings The study offers invaluable insights into the CFFs that impede the successful implementation of LSS 4.0 within organizations. The findings emphasize that “lack of top management commitment and support” is the most significant factor. Using the ISM technique, these factors are categorized into four distinct hierarchical levels: top management-related issues, alignment of LSS 4.0 with organizational strategy, LSS 4.0 readiness and effective implementation challenges. Complementing this, MICMAC analysis groups the CFFs based on their driving and dependence power, while DEMATEL distinguishes them as cause-and-effect factors hindering LSS 4.0 implementation. Originality/value This study extends existing knowledge by uncovering novel, implementation-specific CFFs of LSS 4.0. By combining an extensive literature review, expert surveys, expert opinions and the application of a combined ISM, MICMAC and DEMATEL approach, this research provides a hierarchical model and identifies cause-and-effect relationships among the factors that influence the success of LSS 4.0. The prioritization of CFFs for LSS 4.0 adoption adds a novel dimension to this study.