Development of an IoT integrated DMAIC model for process improvement in Indian SMEs: An empirical study

Abstract

Lean Six Sigma (LSS) and the Internet of Things (IoT) facilitate an organisation to compete in the global market. The benefits of implementing the above-mentioned approaches were not realised by many Indian SMEs. The Indian SMEs contribute nearly about 30% of the country's GDP. Hence, this work focused on how Lean Six Sigma and the Internet of Things were deployed to improve the process performance in an Indian SME. IoT integrated LSS model was implemented to minimise lead time and enhance the quality of the product. Value Stream Mapping and line balancing techniques were used to minimise the lead time. To improve quality and service, an IoT-enabled in-house testing procedure was adopted and based on customer feedback, an android application was also developed to monitor the critical parameters at the customer end to enable preventive maintenance. An Augmented Reality based application was developed to simulate the sequence of the assembly process to facilitate training for the workers. To assess the benefits of implementation, a survey was conducted among people at various levels in the organization. This research resulted in a reduction of assembly lead time from 63.8 min to 24.4 min and an improvement in sigma level from 3.9 to 4.7. In the responses received from the survey, key issues faced during the implementation of the proposed model were identified. Key issues like resistance to change, poor interpersonal, lack of training, poor autonomy, timely decision making, and demand fluctuations during implementation are to be addressed for further effective implementation. The proposed model enhances the overall performance of the process in the manufacturing industry. Furthermore, it creates a driveway for Indian SMEs towards Industry 4.0.