Applying Lean Six Sigma to Optimize Green Hydrogen Production Processes with a Focus on Safety, Health, and Wellbeing

Abstract

The global energy transition towards decarbonization has positioned green hydrogen as a pivotal sustainable energy solution. However, its production faces significant challenges, including inefficiencies, high costs, and safety risks. This study explores the application of Lean Six Sigma (LSS) methodologies to optimize green hydrogen production processes, with a particular focus on enhancing safety, health, and wellbeing (SHW) across the value chain. By integrating SHW considerations into the LSS framework, the research aims to create a holistic approach that not only improves efficiency but also ensures the safety and wellbeing of workers and communities. The study employs the DMAIC (Define, Measure, Analyze, Improve, Control) framework to address key challenges in green hydrogen production, such as energy inefficiencies and safety hazards. Results demonstrate a 15% reduction in energy consumption (from 55 kWh/kg to 47 kWh/kg) and significant improvements in safety and employee satisfaction following LSS implementation. The findings highlight the potential of LSS to drive sustainable and socially responsible hydrogen production, offering a blueprint for the integration of process optimization with SHW priorities in the emerging green hydrogen sector.