Integration of Lean Six Sigma and IOT-Based Real-Time Monitoring for Workplace Hazard Reduction in Industrial Facilities

Abstract

This study examined the integration of Lean Six Sigma and IoT-based real-time monitoring for workplace hazard reduction in industrial and enterprise facility cases, addressing the persistent problem that conventional safety systems often depend on periodic inspections, manual reporting, and reactive corrective action, which may delay hazard detection and control. The purpose of the study was to determine whether structured process-improvement practices and real-time digital monitoring jointly improve hazard reduction outcomes in industrial facilities. A quantitative, cross-sectional, case-based research design was applied using primary questionnaire data collected from managers, supervisors, engineers, safety officers, technicians, and operational staff across selected enterprise/industrial cases. Out of 320 distributed questionnaires, 286 valid responses were analyzed, producing an effective response rate of 89.4%. The key variables were Lean Six Sigma implementation, IoT-based real-time monitoring, and workplace hazard reduction. The analysis plan included descriptive statistics, reliability testing, Pearson correlation, multiple regression, and interaction-effect testing. Findings showed that Lean Six Sigma recorded a positive grand mean of 3.91, IoT-based monitoring recorded a stronger mean of 4.08, and workplace hazard reduction recorded a mean of 4.02. Reliability was strong, with Cronbach’s Alpha values of 0.87 for Lean Six Sigma, 0.89 for IoT monitoring, 0.85 for hazard reduction, and 0.87 for the full instrument. Correlation results showed significant positive relationships between Lean Six Sigma and hazard reduction, r = 0.61, p < .01, and between IoT monitoring and hazard reduction, r = 0.68, p < .01. Regression findings confirmed that Lean Six Sigma, β = 0.29, p < .001, IoT monitoring, β = 0.37, p < .001, and their interaction, β = 0.18, p = .004, significantly predicted hazard reduction, explaining 44.2% of variance, R² = 0.442. The study implies that enterprise safety performance improves most when process discipline, sensor-based visibility, real-time alerts, and corrective-action systems operate as one integrated socio-technical framework.