A lean-six sigma-ergonomics index for assessing shop-floor operational resilience readiness: Method development and SME demonstration.
- 1Department of Industrial and Systems Engineering, Institut Teknologi Sepuluh Nopember (ITS), Surabaya, 60111, Indonesia.
- 2Department of Industrial Engineering, Universitas Tridinanti, Palembang, 30129, Indonesia.
Abstract
Operational resilience readiness at the shop-floor level depends on efficient process flow, stable quality, and adequate human-system capacity, yet these dimensions are commonly assessed separately. This article presents the Lean-Six Sigma-Ergonomics Operational Resilience Index (LSE-ORI), a non-interventional composite method for assessing manufacturing conditions that support resilience readiness. Process-flow efficiency is represented by Process Cycle Efficiency, quality stability by the actual sigma level normalized against a defined target, and human-system capacity by physical, cognitive, and macroergonomic assessments. The scores are standardized to a 0-1 scale and combined multiplicatively to produce the index and identify the lowest-scoring dimension. A two-month demonstration involving 13 operators on a tractor spare-parts production line yielded scores of 0.60, 0.54, and 0.62, resulting in an ORI of approximately 0.20. Quality stability was the lowest-scoring primary component, while work-system structural support was the weakest subcomponent within the human-system. Content validation by 15 experts across 64 items produced a minimum I-CVI of 0.933 and an S-CVI/Ave of 0.995, supporting applicability, calculation traceability, and content validity. Main advantages of the proposed method: • Integrates three shop-floor dimensions into one assessment. • Uses operational data without changing the production system. Provides hierarchical diagnosis of the lowest-scoring component.
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BibTeX
@article{maryadi2026leansix,
title = {{A lean-six sigma-ergonomics index for assessing shop-floor operational resilience readiness: Method development and SME demonstration.}},
author = {Deri Maryadi and Moses Laksono Singgih and Dyah Santhi Dewi},
journal = {MethodsX},
year = {2026},
month = oct,
doi = {10.1016/j.mex.2026.104188},
url = {https://europepmc.org/article/MED/42898655},
note = {CC BY},
}
RIS
TY - JOUR
TI - A lean-six sigma-ergonomics index for assessing shop-floor operational resilience readiness: Method development and SME demonstration.
AU - Deri Maryadi
AU - Moses Laksono Singgih
AU - Dyah Santhi Dewi
PY - 2026
DA - 2026/10/02
JO - MethodsX
DO - 10.1016/j.mex.2026.104188
UR - https://europepmc.org/article/MED/42898655
AB - Operational resilience readiness at the shop-floor level depends on efficient process flow, stable quality, and adequate human-system capacity, yet these dimensions are commonly assessed separately. This article presents the Lean-Six Sigma-Ergonomics Operational Resilience Index (LSE-ORI), a non-interventional composite method for assessing manufacturing conditions that support resilience readiness. Process-flow efficiency is represented by Process Cycle Efficiency, quality stability by the actual sigma level normalized against a defined target, and human-system capacity by physical, cognitive, and macroergonomic assessments. The scores are standardized to a 0-1 scale and combined multiplicatively to produce the index and identify the lowest-scoring dimension. A two-month demonstration involving 13 operators on a tractor spare-parts production line yielded scores of 0.60, 0.54, and 0.62, resulting in an ORI of approximately 0.20. Quality stability was the lowest-scoring primary component, while work-system structural support was the weakest subcomponent within the human-system. Content validation by 15 experts across 64 items produced a minimum I-CVI of 0.933 and an S-CVI/Ave of 0.995, supporting applicability, calculation traceability, and content validity. Main advantages of the proposed method: • Integrates three shop-floor dimensions into one assessment. • Uses operational data without changing the production system. Provides hierarchical diagnosis of the lowest-scoring component.
SN - 2215-0161
ER -