Exploring the Integration of Artificial Intelligence into Lean Six Sigma Methodologies: A Roadmap for Enhancing Manufacturing Efficiency and Quality

Combining artificial intelligence (AI) together with Lean Six Sigma (LSS) methods, especially the DMAIC framework (Define, Measure, Analyse, Improve, Control), has become a revolutionary way to make manufacturing processes better. This study looks at how AI and DMAIC can work together to improve operations. It focuses on how AI technologies can be added to each step of the DMAIC process. By applying artificial intelligence, prescriptive analytics, and simulation models, optimising process changes in the enhancement stage decreases cycle durations, minimises waste, and reduces related expenses. AI-powered real-time monitoring and automated alerts help the control phase stay consistent and reduce deviations by means of which it gains advantage. The research framework conceptually explains the development of DMAIC and the synergy among artificial intelligence tools. The data supports three main hypotheses H1) AI reduces variability and improves defect identification; H2) AI-driven analytics accelerates process enhancements; and H3) AI-based monitoring systems stabilise processes. Combining artificial intelligence with DMAIC provides the process of continuous growth that links operational performance to business objectives. This convergence improves manufacturing’s competitiveness by facilitating more effective data-driven decision-making, process optimisation, and quality assurance.