Purpose The aim of the study is to develop and apply a continuous improvement (CI) framework by introducing environmental considerations into the Six Sigma DMAIC (define–measure–analyze–improve–control) cycle for a continuous identification, evaluation and implementation of promising opportunities of enhancing environmental sustainability of process-based industries. Design/methodology/approach Action research approach within the research design of a single case study was used for illustrating the application of the proposed DMAIC framework for improving operational and environmental performance in the process-industry environment of a pharmaceutical manufacturing company. Findings The case study illustrated the implementation of DMAIC cycle for optimizing the energy consumption of pharmaceutical plants producing bulk drugs for medication. After improving the energy distribution in the cooling tower (CTW), chilled brine (CHB) and chilled water (CHW) system, the pharmaceutical plant was able to achieve an annual economic benefit of US$97,047 and environmental benefits of mitigating CO2 emissions of 807.44 t (CO2) by reducing the electricity and furnace oil consumption. Originality/value The framework may be adopted for environmental considerations specific to process-based industry such as chemical plant, fertilizer units, thermal power plant and food processing industry.
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