Implementing Lean Manufacturing Techniques to Achieve Six Sigma

Abstract

This paper presents how lean manufacturing techniques such as one piece flow, kanban, and u-shaped cells were used to achieve six sigma through continuous improvement efforts and reducing non-value-adding processes in a case study. the objective of the project implementation was to improve quality to a Six Sigma level using Define-Measure-Analyze-Improve-Control (DMAIC) methodology and implementing lean manufacturing techniques. Six Sigma is a continuous improvement technique with a goal of 3.4 defects per million. in this case study, Six Sigma tools are applied to a process that is incurring an unacceptable level of defects and not meeting production requirements. the initial process was mapped and analyzed to collect data on defect levels, work in process, cycle times, product throughput, machine utilization, and labor utilization. Then an alternative process layout utilizing several lean manufacturing techniques including kanban, cellular manufacturing, line balancing, one-piece flow, and a pull system was implemented. Finally, after applying effective poke yokes, standard operating procedures and training, the revised process was compared to the initial process to quantify the results of the improvements. the results included an improvement from 2.6 to 2.8 sigma level, a 43% reduction in defects, 72% increase in production, machine utilization increase of 50%, labor utilization increase of 25%, labor cost reduction of 33% and a work-in-process reduction of 97%.

Department(s)

Engineering Management and Systems Engineering

Document Type

Article - Conference proceedings

Document Version

Citation

File Type

text

Language(s)

English

Rights

© 2024 Scimago Journal & Country Rank, All rights reserved.

Publication Date

01 Dec 2004

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