The r-evolution of Lean Six Sigma from Industry 4.0 to Society 5.0: Excellence 5.0

Purpose – The Excellence 5.0 (EX5.0) model provides a strategic framework for enhancing operational, environmental, social and digital performance, aiding the organizations to reach the highest level of performances, in the least time possible, with the best manner, and by working synergically on process optimization, on improved interpersonal behaviors and on a proper use of new technologies. Design/methodology/approach – The EX5.0 model is based on three pillars: Process Excellence, Human Excellence and Digital Excellence. Findings – The proposed method was applied to optimize the profiling process at an automotive plant, addressing recurring issues such as high defect rates, machine downtime and environmental impact. The improvement project achieved an overall problems’ reduction, thanks to key interventions like machine upgrades, revised procedures and enhanced maintenance practices, resulting in significant operational and environmental improvements. Practical implications – This is the first study to use EX5.0 model to improve operational efficiency and environmental impact via employee engagement, and digital transformation, fostering a culture of continuous improvement. Originality/value – This new model represents an innovative and holistic approach for sustaining a Continuous and Sustainable Improvement culture in the organizations over time, by integrating human, process and digital dimensions.