The Integration of Lean Six Sigma Solutions and Emerging Technologies for Resilient Manufacturing in the Rail Transportation Sector in South Africa

Promoting manufacturing excellence relies on the synergy between existing operations techniques and future technology as the cornerstone of digital manufacturing restructuration. This paper investigates the integration of Lean Six Sigma (LSS) solutions and emerging technologies for resilient manufacturing in the rail transportation sector in South Africa. This study applies cause-effect and technology-organisation-environment analyses to support the LSS methodologies namely Define, Measure, Analyze, Improve, Control (DMAIC) and Define, Measure, Analyze, Design, Verify (DMADV) for existing and innovative processes. The case study of Gibela-Rail Consortium is applied using its integrated manufacturing reports. Findings revealed that smart technologies like big Industrial Internet of Things (IIoT), advanced analytics, sensors, manufacturing systems, Artificial Intelligence (AI), blockchain and digital twin enable connectivity, automation, process streamlining, green practices, quality control, Just-in-time production, embedded policies, and integrated descriptive, prescriptive and predictive analytics for enhanced decision-making processes. Applying LSS and smart technologies enhances cost reduction, zero-waste, production increase enhanced maintenance, lightweight and energy-efficient trains, operational efficiency, passenger satisfaction and competitive advantage. The proposed Smart LSS (LSS4.0)-enabled Resilient Manufacturing Model combines lean techniques and smart technologies to enable resilient manufacturing and continuous improvement. Transport manufacturing companies should adopt a digital change culture enabling process revitalisation and the SA government should upgrade regulations and infrastructure to support digital and green transformation for long-term value creation.