Providing an Integrated Model of Lean Six Sigma and Supply Chain Resilience and Analyzing Its Effects on Improving Flexibility in Industries
Keywords:
Lean Six Sigma, resilient supply chain, content analysis, fuzzy inference system, industrial managementAbstract
The purpose of this study is to design and validate an integrated model of Lean Six Sigma and resilient supply chain management across various industries by evaluating the effects of lean tools on resilience indicators. The research employed an exploratory mixed-methods approach implemented in four stages: content analysis to identify key factors, interpretive structural modeling to develop the conceptual model, a fuzzy inference system to assess the effects, and design of experiments to validate the model. The statistical population consisted of twelve experts, including industrial engineering specialists and managers active in different industries, selected through purposive and snowball sampling. Data collection instruments included semi-structured interviews and NVivo version 11, MATLAB, and Minitab software. Content analysis resulted in the extraction of sixty-six open codes, twenty-four axial categories, and eleven selective categories, which led to identifying eight lean tools—including 5S, Poka-Yoke, QFD, SMED, FMEA, benchmarking, SIPOC, and BSC—and three resilience indicators: flexibility, capacity, and adaptability. Data saturation was achieved after the twelfth interview. Findings from interpretive structural modeling indicated that 5S and QFD serve as driving variables at lower levels and influence intermediate variables and resilience outcomes at higher levels. Results of the design of experiments using fractional factorial designs showed that 5S, with a coefficient of 15.3, had the greatest impact on flexibility and capacity, while QFD had the strongest effect on adaptability. The fuzzy inference system results further confirmed these findings. Periodic review of the supply chain using benchmarking at medium or high levels is recommended.
References
Asadi, F. (2019). The role of Six Sigma in improving the quality of services in healthcare institutions. 2. https://www.sid.ir/paper/130088/fa
Bagherimanesh, M., Kavyani, H., Hashemi Rad, M., & Habibi, H. (2019). The mediating role of organizational innovation in explaining organizational learning on supply chain resilience (Case study: A defense organization). Andisheh Amad, 18(69), 1-25. https://www.sid.ir/paper/404286/fa
Christopher, M., & Peck, H. (2023). Building the resilient supply chain. The International Journal of Logistics Management, 15(2), 1-14. https://doi.org/10.1108/09574090410700275
Gomaa, A. H. (2022). Lean six sigma for improving supply chain management-A literature review. British Food Journal, 118(5). https://www.researchgate.net/profile/Attia-Gomaa-2/publication/381128821_Lean_six_sigma_for_improving_supply_chain_management_-A_literature_review/links/6667fe27b769e769192a0383/Lean-six-sigma-for-improving-supply-chain-management-A-literature-review.pdf
Hall, A., Beck, E., & Hall, L. (2022). Developing a capacity for organizational resilience through strategic human resource management. Human Resource Management Review, 21, 243-255. https://doi.org/10.1016/j.hrmr.2010.07.001
Hamzeh Herandi, A. (2021). An overview of Six Sigma and its effectiveness on organizational performance with a focus on organizational quality management (Case study: Tehran Municipality). The Fourth International Conference on Knowledge and Technology of the Third Millennium in Economics, Management, and Accounting, Tehran.
Hojjati, S. M. H., & Mohsen Zarei, N. (2019). A new method for weighting customer requirements and prioritizing product technical features using a fuzzy QFD approach. Journal of Industrial Engineering and Management, 30(1). https://elmnet.ir/doc/887241-12281
Hundal, G. S., Thiyagarajan, S., Alduraibi, M., Laux, C. M., Furterer, S. L., Cudney, E. A., & Antony, J. (2022). The impact of Lean Six Sigma practices on supply chain resilience during COVID 19 disruption: a conceptual framework. Total Quality Management & Business Excellence, 33(15-16), 1913-1931. https://doi.org/10.1080/14783363.2021.2014313
Jüttner, U., & Maklan, S. (2022). Supply chain resilience in the global financial crisis: An empirical study. Supply Chain Management: Int. J., 16(4), 246-259. https://doi.org/10.1108/13598541111139062
Khajavi, M., & Mohammadi, F. (2020). Investigating the relationship between Lean production and Six Sigma in increasing productivity at Wagon Pars Arak. The First International Conference on Challenges and Innovative Solutions in Industrial Engineering, Management, and Accounting,
Khodaei, M. (2021). Study and analysis of the factors influencing value creation in organizations, with the mediating role of optimal error management using Lean Six Sigma in organizations. The Sixth International Conference on New Research in Counseling, Educational Sciences, and Psychology, Tehran.
Kolawole, O. A., Mishra, J. L., & Hussain, Z. (2021). Addressing food waste and loss in the Nigerian food supply chain: Use of Lean Six Sigma and Double-Loop Learning. Industrial Marketing Management, 93, 235-249. https://doi.org/10.1016/j.indmarman.2021.01.006
Kusumastuti, R. Y., Mulyati, H., & Suprayitno, G. (2021). Disclosure integration of lean six sigma principles in sustainable supply chain in poultry industry. Indonesian Interdisciplinary Journal of Sharia Economics (Iijse), 4(1), 300-312. https://doi.org/10.31538/iijse.v4i1.1706
Lorestani, P. (2018). Six Sigma: A necessity, not an option. The Second National Conference on Accounting, Management, and Economics with a focus on sustainable employment and its role in industrial growth,
Ma, K., Zhou, J., & Liu, H. (2025). Artificial intelligence, supply chain flexibility, and firm performance. International Journal of Production Economics, 281, 109782. https://doi.org/10.1016/j.ijpe.2025.109782
Madhani, P. M. (2020). Enhancing supply chain efficiency and effectiveness with Lean Six Sigma approach. International Journal of Project Management and Productivity Assessment (IJPMPA), 8(1), 40-65. https://doi.org/10.4018/IJPMPA.2020010103
Masini, S. E., Nicolay, C. R., & Darzi, A. (2017). The use of Lean and Six Sigma methodologies in surgery: A systematic review. The Surgeon, 13(2), 91-100. https://doi.org/10.1016/j.surge.2014.08.002
Mohammadi, M., & Shayannia, S. A. (2023). Identifying and prioritizing effective factors in the successful implementation of Lean Six Sigma projects in the automotive industry. Journal of Operations Management, 3(10). https://journals.iau.ir/article_709773.html
Mohapatra, B., Tripathy, S., & Singhal, D. (2023). A sustainable solution for lean barriers through a fuzzy DEMATEL methodology with a case study from the Indian manufacturing industry. International Journal of Lean Six Sigma, 14(4), 815-843. https://doi.org/10.1108/IJLSS-06-2022-0134
Pettit, T. J., Fiksel, J., & Croxton, K. L. (2021). Ensuring supply chain resilience: development of a conceptual framework. Journal of Business Logistics, 31(1), 1-21. https://doi.org/10.1002/j.2158-1592.2010.tb00125.x
Prajogo, D., & Olhager, J. (2023). Supply chain integration and performance: The effects of long-term relationships, information technology and sharing, and logistics integration. International Journal of Production Economics, 135(1). https://doi.org/10.1016/j.ijpe.2011.09.001
Rahman, M. K., Hossain, M. A., Piprani, A. Z., & Abdullah, A. R. (2025). Impact of tech-driven integration, flexibility, and ambidexterity on supply chain integration and performance in manufacturing firms: moderating role of uncertainty and agility. Future Business Journal, 11(1), 72. https://doi.org/10.1186/s43093-025-00488-9
Rana, J. A., & Jani, S. Y. (2023). Enhancing sustainable supply chain performance by adopting sustainable lean six sigma-Industry 4.0 practices. Management of Environmental Quality: An International Journal, 34(4), 1198-1221. https://doi.org/10.1108/MEQ-04-2022-0122
Rash, S., Ifti, M., & Ebrahimpour, M. (2024). Evaluation of the quality of manufactured products using an ANFIS-based fuzzy neural network approach (Case study: Khazar Plastic Manufacturing and Industrial Company). Journal of Industrial Management Perspectives, 14(1), 114-134. http://journals.sbu.ac.ir/article_104223.html
Sarlak, D. (2021). Study and analysis of factors influencing organizational quality enhancement with the mediating role of Lean Six Sigma and its optimal implementation at the organizational level (Case study: Tehran Municipality). The Fourth International Conference on Knowledge and Technology of the Third Millennium in Economics, Management, and Accounting, Tehran.
Sharafi, M., Fadaei, M., & Hassan Daei, N. (2023). Identifying Lean Six Sigma indicators and their impact on performance (Case study: Isfahan Steel Company). The First International Conference on Management Capabilities, Industrial Engineering, Accounting, and Economics, Babol.
Sheikh Shoa'i, H. (2021). A composite framework for Green Lean Six Sigma (GLSS) for sustainable development policymaking. International Conference on Management and Industry,
Tay, H. L., & Aw, H. S. (2021). Improving logistics supplier selection process using lean six sigma-an action research case study. Journal of Global Operations and Strategic Sourcing, 14(2), 336-359. https://doi.org/10.1108/JGOSS-05-2020-0025
Tveiten, C. K. (2023). Building resilience into emergency management. Safety Science, 50, 1960-1966. https://doi.org/10.1016/j.ssci.2012.03.001
Vachon, S., & Klassen, R. D. (2022). An exploratory investigation of the effects of supply chain complexity on delivery performance. Engineering Management, IEEE Transactions on, 49(3). https://doi.org/10.1109/TEM.2002.803387
Widiwati, I. T. B., Liman, S. D., & Nurprihatin, F. (2024). The implementation of Lean Six Sigma approach to minimize waste at a food manufacturing industry. Journal of Engineering Research. https://doi.org/10.1016/j.jer.2024.01.022
Yavari, M., & Aghalan, M. (2019). Redesigning the supply chain network to create resilience capabilities by introducing the strategy of forming alliances. Journal of Industrial Engineering and Management, 35(2.1), 139-152. https://sjie.journals.sharif.edu/article_21320.html
Downloads
Published
Submitted
Revised
Accepted
Issue
Section
License
Copyright (c) 2026 Maryam Anjom Shoa , Mozhde Rabbani, Hasan Dehghan Dehnavi , Mohammad Taghi Honary (Author)
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
