Optimizing Manufacturing Supply Chains Using a Strategic Lean Six Sigma Framework: A Case Study

Abstract

Manufacturing supply chains are increasingly vulnerable to disruptions, inefficiencies, and market volatility, necessitating enhanced resilience to remain competitive. This study explores the integration of Lean Six Sigma (LSS) with strategic planning to optimize supply chain operations and align them with broader organizational goals. The focus is on reducing waste, improving efficiency, managing risks, minimizing costs, enhancing product quality, and securing a sustainable competitive advantage. Additionally, the research examines LSS applications in developing countries, where resource limitations, market instability, and infrastructure gaps significantly affect supply chain performance. The aim is to identify strategies that improve efficiency, resilience, and competitiveness while supporting sustainable growth in these regions. The study highlights the synergies between LSS and strategic planning, especially in mitigating risks and enhancing adaptability. Using the DMAIC framework and key performance indicators (KPIs), it evaluates the impact of LSS on procurement, operations, inventory management, and customer satisfaction. A conceptual framework is proposed to integrate LSS and strategic planning across supply chain functions, ensuring alignment with long-term business goals. A case study of an Egyptian electrical control panel manufacturer demonstrates the practical application of this approach, showcasing improvements in key supply chain functions. The findings offer valuable insights for academics and practitioners seeking to enhance supply chain resilience, mitigate risks, and sustain a competitive advantage in a rapidly evolving global market. The study also provides actionable guidance on using LSS tools to optimize performance and align operations with strategic objectives.