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<p>This study aims to develop and apply a Sustainable Lean Six Sigma (SLSS) framework to improve sustainable manufacturing performance in the concrete paving block (CPB) industry. The research employs the DMAIC methodology, combining SIPOC and Delphi validation at the Define stage, Manufacturing Sustainability Index (MSI) and Analytic Hierarchy Process (AHP)-based weighting at the Measure stage, and a traffic light system at the Analyze stage to identify critical inefficiencies. Improvement priorities were determined using Failure Mode and Effect Analysis (FMEA) and TOPSIS, while the Control phase utilized check sheets to sustain corrective actions. The findings reveal six indicators with efficiency scores below 80%, including time efficiency (53%), energy use (57%), occupational safety (68%), employee training (0%), mental workload (69%), and physical workload (49%). Among these, employee training recorded the most critical failure mode with the highest Risk Priority Number (RPN) of 504, followed by occupational safety risks in stone crusher operations (288) and warehouse storage (240). Improvement alternatives were then prioritized using TOPSIS, where the adoption of comprehensive personal protective equipment (PPE) and hazard signage achieved the highest ranking (CCj = 0.6261), while job rotation was ranked lowest (CCj = 0.3929). The Control stage demonstrated that check sheets effectively sustained improvements by ensuring compliance and continuous monitoring. This study contributes to the literature by providing empirical evidence and a structured SLSS-based framework that integrates economic, environmental, and social dimensions into sustainable manufacturing improvement.</p>

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Integrating Lean Six Sigma, Delphi, AHP and TOPSIS for Waste Minimization in Sustainable Manufacturing: A Case of Concrete Paving Block (CPB) Production

  • 期刊论文

  • 发表日期：

    2026年4月24日

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  • Tyas Yuli Rosiani,
  • Rovie Irya Septian,
  • Ilyas Masudin

摘要

This study aims to develop and apply a Sustainable Lean Six Sigma (SLSS) framework to improve sustainable manufacturing performance in the concrete paving block (CPB) industry. The research employs the DMAIC methodology, combining SIPOC and Delphi validation at the Define stage, Manufacturing Sustainability Index (MSI) and Analytic Hierarchy Process (AHP)-based weighting at the Measure stage, and a traffic light system at the Analyze stage to identify critical inefficiencies. Improvement priorities were determined using Failure Mode and Effect Analysis (FMEA) and TOPSIS, while the Control phase utilized check sheets to sustain corrective actions. The findings reveal six indicators with efficiency scores below 80%, including time efficiency (53%), energy use (57%), occupational safety (68%), employee training (0%), mental workload (69%), and physical workload (49%). Among these, employee training recorded the most critical failure mode with the highest Risk Priority Number (RPN) of 504, followed by occupational safety risks in stone crusher operations (288) and warehouse storage (240). Improvement alternatives were then prioritized using TOPSIS, where the adoption of comprehensive personal protective equipment (PPE) and hazard signage achieved the highest ranking (CCj = 0.6261), while job rotation was ranked lowest (CCj = 0.3929). The Control stage demonstrated that check sheets effectively sustained improvements by ensuring compliance and continuous monitoring. This study contributes to the literature by providing empirical evidence and a structured SLSS-based framework that integrates economic, environmental, and social dimensions into sustainable manufacturing improvement.