Manufacturing supply chain excellence through Lean Six Sigma: A case study approach

Article ID: 2032

Abstract

Manufacturing supply chains often struggle with persistent challenges such as inefficiencies, production delays, and rising operational costs—factors that can significantly impact performance, profitability, and market competitiveness. These challenges are especially pronounced in developing countries, where limited resources, infrastructure deficits, and economic volatility further complicate supply chain operations. This study explores the strategic integration of Lean Six Sigma (LSS) to address these issues by enhancing operational efficiency, eliminating waste, and reducing process variability across key functions, including procurement, production, inventory management, and distribution. Applying the DMAIC (Define, Measure, Analyze, Improve, Control) methodology alongside key performance indicators (KPIs), the research assesses the effectiveness of LSS in optimizing supply chain performance. A case study of an Egyptian electrical control panel manufacturer highlights significant improvements, including a 10% increase in first-time product quality, a 35% reduction in processing time, and notable gains in equipment efficiency, customer satisfaction, and value-added production. These results demonstrate the practical value of LSS in achieving measurable, sustainable improvements within manufacturing supply chains. Furthermore, the study introduces a conceptual framework that aligns LSS implementation with long-term strategic goals, fostering a culture of continuous improvement and supporting organizational resilience. The findings provide actionable insights for researchers and practitioners, emphasizing how LSS can be leveraged to drive operational excellence, align strategy with execution, and enhance competitive positioning—particularly in complex, resource-constrained environments.