Integration of IR 4.0 Into Six Sigma for Sustainability in Malaysia Manufacturing Industry

Authors

  • Muslim Diekola Akanmu Universiti Malaysia Perlis, 01000 Kangar, Perlis, Malaysia
  • Norshahrizan Nordin Universiti Malaysia Perlis, 01000 Kangar, Perlis, Malaysia

Keywords:

Contingency Theory, Industrial Revolution 4.0 Technologies, Practice-based View, Six Sigma Practices, Sustainable Performance

Abstract

The high competition among manufacturing companies in relation to the food and beverages industry has triggered the industry to evolve into a smart manufacturing system. The present reviewed literature reveals the relationship between industrial revolution 4.0 technologies (IR tech), six-sigma (SS) and sustainable performance. Studies have shown that six sigma practices have significantly impacted organizational performance in the manufacturing industry. However, the integrated effects of six-sigma practices and IR 4.0 technologies on sustainable performance are yet to be empirically investigated in the context of the food and beverage industry in Malaysia. Therefore, this research intends to address the gap by having a preliminary conceptual approach to the joint effect of SS and IR 4.0 technologies on sustainable performance by reviewing, analyzing and synthesizing previous studies. The study aims to confirm the future direction of the food and beverages industry that is recently employing new technologies in its manufacturing system. The consequent study shall be based on data collection from middle management employees who are working and familiar with the production phases of the industry. This study is pivoted from the theories of practice-based view and contingency posing as the underpinning theories. The study reaffirms the importance of operations management practices for any strategic implementation to be successful and how sustainable performance is enhanced through performance variations.

References

Abualfaraa, W., Salonitis, K., Al-Ashaab, A., & Ala’raj, M. (2020). Lean-green manufacturing practicesand their link with sustainability: A critical review. Sustainability, 12(3), 981.https://doi.org/10.3390/su12030981

Ahuett-Garza, H., & Kurfess, T. (2018). A brief discussion on the trends of habilitating technologies for industry 4.0 and smart manufacturing. Manufacturing Letters, 15, 60-63.https://doi.org/10.1016/j.mfglet.2018.02.011

Akanmu, M. D., Hassan, M. G., & Bahaudin, A. Y. B. (2020). A preliminary analysis modeling of the relationship between quality management practices and sustainable performance. Quality Management Journal, 27(1), 37-61. https://doi.org/10.1080/10686967.2019.1689800

Akanmu, M. D., Hassan, M. G., Mohamad, B., & Nordin, N. (2021). Sustainability through TQMpractices in the food and beverages industry. International Journal of Quality & Reliability Management, Vol. ahead-of-print No. ahead-of-print. https://doi.org/10.1108/IJQRM-05-2021-0143

Antony, J., & Sony, M. (2019). An empirical study into the limitations and emerging trends of Six Sigma in manufacturing and service organisations. International Journal of Quality & Reliability Management, 37(3), 470–493. https://doi.org/10.1108/ijqrm-07-2019-0230

Antony, J., Snee, R., & Hoerl, R. (2017). Lean Six Sigma: yesterday, today and tomorrow. International Journal of Quality & Reliability Management, 34(7), 1073–1093. https://doi.org/10.1108/ijqrm-03-2016-0035

Aqlan, F., & Al-Fandi, L. (2018). Prioritizing process improvement initiatives in manufacturingenvironments. International Journal of Production Economics, 196, 261-268.https://doi.org/10.1016/j.ijpe.2017.12.004

Brito, M. F., Ramos, A. L., Carneiro, P., & Gonçalves, M. A. (2019). Ergonomic analysis in leanmanufacturing and industry 4.0—A systematic review. In Lean Engineering for Global Development (pp. 95-127). Springer, Cham. https://doi.org/10.1007/978-3-030-13515-7_4

Bromiley, P., & Rau, D. (2016). Missing the point of the practice-based view. Strategic Organization,14(3), 260-269. https://doi.org/10.1177/1476127016645840

Buer, S. V., Strandhagen, J. O., & Chan, F. T. (2018). The link between Industry 4.0 and leanmanufacturing: mapping current research and establishing a research agenda. International Journalof Production Research, 56(8), 2924-2940. https://doi.org/10.1080/00207543.2018.1442945

Carvalho, N., Chaim, O., Cazarini, E., & Gerolamo, M. (2018). Manufacturing in the fourth industrialrevolution: A positive prospect in sustainable manufacturing. Procedia Manufacturing, 21, 671-678. https://doi.org/10.1016/j.promfg.2018.02.170

Chakravorty, S. S. (2010). Where process-improvement projects go wrong. Wall Street Journal,255(19). https://www.wsj.com/articles/SB10001424052748703298004574457471313938130

Chen, Y., Okudan, G. E., & Riley, D. R. (2010). Sustainable performance criteria for constructionmethod selection in concrete buildings. Automation in Construction, 19(2), 235–244.https://doi.org/10.1016/j.autcon.2009.10.004

D’Andreamatteo, A., Ianni, L., Lega, F., & Sargiacomo, M. (2015). Lean in healthcare: acomprehensive review. Health policy, 119(9), 1197-1209.https://doi.org/10.1016/j.healthpol.2015.02.002

Da Xu, L., He, W., & Li, S. (2014). Internet of things in industries: A survey. IEEE Transactions onindustrial inform Informatics, 10(4), 2233–2243. https://doi.org/10.1109/tii.2014.2300753

Despeisse, M, Mbaye, F, Ball, PD, & Levers, A. (2012). The emergence of sustainable manufacturingpractices. Production Planning and Control: The Management of Operations, 23(5), 354–376.https://doi.org/10.1080/09537287.2011.555425

Doh, S. W., Deschamps, F., & de Lima, E. P. (2016). Systems Integration in the Lean Manufacturing Systems Value Chain to Meet Industry 4.0 Requirements. In ISPE TE (pp. 642-650).

Dora, M., Van Goubergen, D., Kumar, M., Molnar, A., & Gellynck, X. (2014). Application of leanpractices in small and medium-sized food enterprises. British Food Journal.https://doi.org/10.1108/BFJ-05-2012-0107

Drohomeretski, E., Gouvea da Costa, S. E., Pinheiro de Lima, E., & Garbuio, P. A. D. R. (2014). Lean, Six Sigma and Lean Six Sigma: an analysis based on operations strategy. International Journal of Production Research, 52(3), 804-824. https://doi.org/10.1080/00207543.2013.842015

Dunphy, D. (2011). Chapter 1 Conceptualizing Sustainability: The Business Opportunity", Gabriel Eweje, Martin Perry, in (ed.) Business and Sustainable: Concepts, Strategies and Changes (Critical Studies on Corporate Responsibility, Governance and Sustainable (Vol. 3): Emerald Group Publishing Limited. https://doi.org/10.1108/S2043-9059 (2011)0000003009

Eweje, G. (2011). Chapter 7 Managerial Perceptions of Sustainable ", Gabriel Eweje, Martin Perry, in(ed.) Business and Sustainability: Concepts, Strategies and Changes (Critical Studies on Corporate Responsibility, Governance and Sustainable (Vol. 3): Emerald Group Publishing Limited.https://doi.org/10.1108/S2043-9059 (2011)0000003015

Fatorachian, H., & Kazemi, H. (2018). A critical investigation of Industry 4.0 in manufacturing:theoretical operationalisation framework. Production Planning & Control, 29(8), 633-644.https://doi.org/10.1080/09537287.2018.1424960

FMM Directory (2017). Member Directory, Federation of Malaysian Manufacturers, Selangor

Guan, Y., Cheng, H., & Ye, Y. (2010). Performance Evaluation of Sustainable Supply Chain Based on AHP and Fuzzy Comprehensive Evaluation. Applied Mechanics and Materials, 26(28), 1004-1007.https://doi.org/10.4028/www.scientific.net/AMM.26-28.1004

Habidin, N, F., & Yusof, S. M. (2012). Relationship between lean six sigma, environmental management system, and organizational performance in Malaysian automotive industry. International Journal of Automotive Technology, 13(7), 1119-1125.https://doi.org/10.1007/s12239-012-0114-4

Habidin, N. F., Zubir, A. F. M., Fuzi, N. M., Latip, N. A. M., & Azman, M. N. A. (2015). Sustainable manufacturing practices in Malaysian automotive industry: confirmatory factor analysis. Journal of Global Entrepreneurship Research, 5(1), 14. https://doi.org/10.1186/s40497-015-0033-8

Hassan, M.G., Akanmu, M.D., and Yusoff R. Z. (2018). Technological integration and sustainable performance in manufacturing firms. International Journal of Technology. Vol. 9(8), pp. 1639-1650. https://doi.org/10.14716/ijtech.v9i8.2747

Hussain, N. H. M., & Byrd, H. (2016). 'Balik Kampong': Is Malaysia Facing the Trends of DeUrbanization? International Journal of the Malay World and Civilisation (Iman), 4(2016), 35-43.

Ivanov, D., Dolgui, A., Sokolov, B., Werner, F., & Ivanova, M. (2016). A dynamic model and analgorithm for short-term supply chain scheduling in the smart factory industry 4.0. International Journal of Production Research, 54(2), 386-402. https://doi.org/10.1080/00207543.2014.999958

Jeble, S., Dubey, R., Childe, S. J., Papadopoulos, T., Roubaud, D., & Prakash, A. (2018). Impact of bigdata and predictive analytics capability on supply chain Sustainability. The International Journalof Logistics Management. https://doi.org/10.1108/IJLM-05-2017-0134

John, A., & Ngoasong, L. (2008). Budgetary and Management Control Process in a Manufacturing: Case of Guinness Nigerian PLC

Kamble, S. S., Gunasekaran, A., & Gawankar, S. A. (2018). Sustainable Industry 4.0 framework: Asystematic literature review identifying the current trends and future perspectives. Process Safetyand Environmental Protection, 117, 408-425. https://doi.org/10.1016/j.psep.2018.05.009

Kamble, S. S., Gunasekaran, A., & Sharma, R. (2018). Analysis of the driving and dependence powerof barriers to adopt industry 4.0 in Indian manufacturing industry. Computers in Industry, 101, 107-119. https://doi.org/10.1016/j.compind.2018.06.004

Karaköse, M., & Yetiş, H. (2017). A cyberphysical system based mass-customization approach withintegration of Industry 4.0 and smart city. Wireless Communications and Mobile Computing, 2017.https://doi.org/10.1155/2017/1058081

Lee, J. Y., Yoon, J. S., & Kim, B. H. (2017). A big data analytics platform for smart factories in smalland medium-sized manufacturing enterprises: An empirical case study of a die casting factory.

International Journal of Precision Engineering and Manufacturing, 18(10), 1353-1361.https://doi.org/10.1007/s12541-017-0161-x

Li, D., Tang, H., Wang, S., & Liu, C. (2017). A big data enabled load-balancing control for smart manufacturing of Industry 4.0. Cluster Computing, 20(2), 1855-1864.https://doi.org/10.1007/s10586-017-0852-1

Liao, Y., Deschamps, F., Loures, E. D. F. R., & Ramos, L. F. P. (2017). Past, present and future of Industry 4.0-a systematic literature review and research agenda proposal. International journal ofproduction research, 55(12), 3609-3629. https://doi.org/10.1080/00207543.2017.1308576

Lin, D., Lee, C. K., Lau, H., & Yang, Y. (2018). Strategic response to Industry 4.0: an empiricalinvestigation on the Chinese automotive industry. Industrial Management & Data Systems.https://doi.org/10.1108/IMDS-09-2017-0403

Liu, Y., & Xu, X. (2017). Industry 4.0 and cloud manufacturing: A comparative analysis. Journal of Manufacturing Science and Engineering, 139(3). https://doi.org/10.1115/1.4034667

Luthra, S., & Mangla, S. K. (2018). Evaluating challenges to Industry 4.0 initiatives for supply chain Sustainability in emerging economies. Process Safety and Environmental Protection, 117, 168-179.https://doi.org/10.1016/j.psep.2018.04.018

Malaysian-German Chamber of Commerce and Industry (MGCC) (2012). Market watch 2012, the

Malaysian automotive and supplier industry.http://www.malaysia.ahk.de/fileadmin/ahk_malaysia/Market_reports_2012/. Accessed 20 November 2014.

Manzouri, M., Ab Rahman, M. N., Saibani, N., & Zain, C. R. C. M. (2013). Lean supply chain practicesin the Halal food. International Journal of Lean Six Sigma. https://doi.org/10.1108/IJLSS-10-2012-0011

Moyne, J., & Iskandar, J. (2017). Big data analytics for smart manufacturing: Case studies insemiconductor manufacturing. Processes, 5(3), 39. https://doi.org/10.3390/pr5030039

Negrão, L. L. L., Godinho Filho, M., & Marodin, G. (2017). Lean practices and their effect onperformance: a literature review. Production Planning & Control, 28(1), 33-56.https://doi.org/10.1080/09537287.2016.1231853

Nordin, N, Deros, B. M., & Wahab, D. A. (2010). Relationship between organizational change and leanmanufacturing implementation in Malaysian automotive industry. (The 11th Asia Pacific Industrial Engineering and Management Systems Conference and the 14th Asia Pacific Regional Meeting of International Foundation for Production Research).

Pei, Y. L., Amekudzi, A. A., Meyer, M. D., Barrella, E. M., & Ross, C. L. (2010). Performancemeasurement frameworks and development of effective sustainable transport strategies andindicators. Journal of the Transportation Research Board, 2163, 73-80.https://doi.org/10.3141/2163-08

PROTON Annual Report. (2011). PROTON Annual Report.http://ir.chartnexus.com/proton/flash/ar_2011/index.html. Accessed 25 December 2014.

Ringle, Christian M., Wende, Sven, & Becker, Jan-Michael. (2015). SmartPLS 3. Bonningstedt: Smart PLS. Retrieved from http://www.smartpls.com

Schroeder, R. G., Linderman, K., Liedtke, C., & Choo, A. S. (2009). Six sigma: definition andunderlying theory. Quality Control and Applied Statistics, 54(5), 441-445.

Scott, B. S., Wilcock, A. E., & Kanetkar, V. (2009). A survey of structured continuous improvementprograms in the Canadian food sector. Food control, 20(3), 209-217.https://doi.org/10.1016/j.foodcont.2008.04.008

Shah, R., Chandrasekaran, A., & Linderman, K. (2008). In pursuit of implementation patterns: thecontext of Lean and Six Sigma. International Journal of Production Research, 46(23), 6679-6699.https://doi.org/10.1080/00207540802230504

Sousa, R., & Voss, C. A. (2008). Contingency research in operations management practices. Journal of Operations Management, 26(6), 697-713. https://doi.org/10.1016/j.jom.2008.06.001

The Sun Daily (2018). Malaysia must keep up with Revolution 4.0. Available at:https://www.thesundaily.my/local/malaysia-must-keep-up-with-revolution-4-0-CI309026

Tortorella, G. L., & Fettermann, D. (2018). Implementation of Industry 4.0 and lean production in Brazilian manufacturing companies. International Journal of Production Research, 56(8), 2975-2987. https://doi.org/10.1080/00207543.2017.1391420

Ullah, AMMS, Hashimoto, H, Kabo, A, & Tamali, J. (2013). Sustainability analysis of rapidprototyping: material/resource and process perspectives. International Journal of Sustainable Manufacturing, 3(1), 20-36. https://doi.org/10.1504/IJSM.2013.058640

Vaidya, S., Ambad, P., & Bhosle, S. (2018). Industry 4.0-a glimpse. Procedia manufacturing, 20, 233-238. https://doi.org/10.1016/j.promfg.2018.02.034

Wagner, T., Herrmann, C., & Thiede, S. (2017). Industry 4.0 impacts on lean production systems. Procedia Cirp, 63, 125-131. https://doi.org/10.1016/j.procir.2017.02.041

Wamba, S. F., Gunasekaran, A., Akter, S., Ren, S. J. F., Dubey, R., & Childe, S. J. (2017). Big data analytics and firm performance: Effects of dynamic capabilities. Journal of Business Research, 70,356-365. https://doi.org/10.1016/j.jbusres.2016.08.009

Yu, Z., Ouyang, J., Li, S., & Peng, X. (2017). Formal modeling and control of cyber-physical manufacturing systems. Advances in Mechanical Engineering, 9(10), 1687814017725472.https://doi.org/10.1177/1687814017725472

Yuan, C, Zhai, Q, & Domfeld, D. (2012). A three dimensional system approach for environmentally sustainable manufacturing. CIRP Annals-Manufacturing Technology, 61(1), 39-42.https://doi.org/10.1016/j.cirp.2012.03.105

Yuan, Z., Qin, W., & Zhao, J. (2017). Smart manufacturing for the oil refining and petrochemical industry. Engineering, 3(2), 179-182. https://doi.org/10.1016/J.ENG.2017.02.012

Zhong, R. Y., Xu, X., Klotz, E., & Newman, S. T. (2017). Intelligent manufacturing in the context of industry 4.0: A review. Engineering, 3(5), 616-630. https://doi.org/10.1016/J.ENG.2017.05.015

Zikmund, W. G., Babin, B. J., Carr, J. C., & Griffin, M. (2010). Business Research Methods (8th Ed.). Canada: Nelson Education, Ltd.

Zink, K. J. (2014). Designing sustainable work systems: The need for a systems approach. Applied Ergonomics, 45(1), 126-132. https://doi.org/10.1016/j.apergo.2013.03.023

Downloads

Published

2025-08-04