Implementing the Lean Sigma Framework in an Indian SME: a case study

Lean and Six Sigma are two widely acknowledged business process improvement strategies available to organisations today for achieving dramatic results in cost, quality and time by focusing on process performance. Lately, Lean and Six Sigma practitioners are integrating the two strategies into a more powerful and effective hybrid, addressing many of the weaknesses and retaining most of the strengths of each strategy. Lean Sigma combines the variability reduction tools and techniques from Six Sigma with the waste and non-value added elimination tools and techniques from Lean Manufacturing, to generate savings to the bottom-line of an organisation. This paper proposes a Lean Sigma framework to reduce the defect occurring in the final product (automobile accessories) manufactured by a die-casting process. The proposed framework integrates Lean tools (current state map, 5S System, and Total Productive Maintenance (TPM)) within Six Sigma DMAIC methodology to enhance the bottom-line results and win customer loyalty. Implementation of the proposed framework shows dramatic improvement in the key metrics (defect per unit (DPU), process capability index, mean and standard deviation of casting density, yield, and overall equipment effectiveness (OEE)) and a substantial financial savings is generated by the organisation

Six Sigma vs Lean : some perspectives from leading academics and practitioners

The purpose of this paper is to present the fundamental and critical differences between two of the most powerful methodologies in a process excellence initiative in any organisation. The approach taken was to collate opinions from a number of leading academics and practitioners from five different countries. It was also important to ensure that all participants have a good knowledge and expertise in the field of both Lean and Six Sigma methodologies. Although both methodologies are focused on process and quality improvement, Lean is formalisation and codification of experience and judgement which is not a feature of Six Sigma. Lean emphasises speed and waste, however Six Sigma emphasises variation, defects and process evaluation. The viewpoints expressed in the article are those of a few academics and practitioners. It is important to capture the viewpoints of more academics and practitioners to arrive at sound and valid conclusions. The paper provides an excellent resource for many researchers and for practitioners who are engaged in research and applications of the most two powerful methodologies for achieving and sustaining operational excellence. It is also critical to understand the fundamental differences between these two methodologies

Lean Six Sigma Leadership in Health Care Organizations

The reason for choosing this topic was the want to change the current employee settings in health care organizations. Using Lean Six Sigma Leadership has been a proven method to increasing staff satisfaction and empowering lifelong learning. The research for Lean Six Sigma ideologies came from reputable sources of literature, actual Lean Six Sigma training, and other publications. The want for providing information on the benefits of using this leadership program comes from future problems in health care administrators communicating to clinical staff and other employee bases. The findings were significant enough to create a compelling argument for the benefits of entire program in health care organization settings

Lean Systems: Soft OR in practice

Lean implementation involves eliminating all forms of waste (for example, defects or overproduction) and consists of many improvement strategies or systems such as mistake proofing (Poka-Yoke) and Single Minute Exchange of Die (a.k.a. quick changeover). The purpose of this study is to discuss a successful lean or waste elimination initiative for a building products company. Specifically, this study describes how mistake proofing and quick changeover systems were implemented using soft OR practices or Soft Systems Methodology (SSM). Essentially, SSM consisted of four sequential stages, namely (1) problem identification, (2) basic approaches to improvement, (3) making plans for improvement, and (4) translating improvement plans into reality. The study contributes in two ways: for practicing managers, it shows that at the core of lean is soft OR practices, and for academicians, it provides directions for future research

Quality prediction in manufacturing system design.

Manufacturing system design can significantly affect the resulting product quality level. Therefore, the early prediction of product quality, as affected by manufacturing system configuration decisions, can enhance the manufacturer\u27s competitiveness through achieving higher quality levels at lower costs in a responsive manner. In this research, a conceptual framework is proposed for the proactive assessment of product quality in terms of the manufacturing system configuration parameters. A new comprehensive model that can be used in comparing different system configurations based on quality is developed using Analytic Hierarchy Process. In addition, a hierarchical fuzzy inference system is developed to model the ill-defined relation between manufacturing system design parameters and the resulting product quality. This model is capable of mapping the considered manufacturing system configuration parameters into a Configuration Capability Indicator (CCI), expressed in terms of sigma capability level, which can be compared to the benchmark Six Sigma capability. The developed models have been applied to several case studies (Test Parts ANC-90 and ANC-101, Cylinder Head Part Family, Gearbox Housing, Rack Bar Machining, and Siemens Jeep Intake Manifold) with different configuration scenarios for illustration and verification. The results demonstrate the capabilities of the CCI in comparing different system configurations from quality point of view and in supporting the decision-making during the early stages of manufacturing system development. The included application of the developed models emphasized that high quality levels can be achieved by investigating all the improvement opportunities and it is recommended that efforts should be directed in the first place to design the system with high defect prevention capability. This can be achieved by using highly capable processes, implementation of mistake proofing techniques, as well as minimizing variability due to parallel processing and variation stack up. Considering the relationship between quality and complexity, it has been concluded that the CCI represents the time-independent real complexity of a system configuration. Furthermore, it has been demonstrated that the product complexity adversely affects the resulting product quality. Therefore, it is recommended that high product quality levels can be achieved not only by using highly capable system configurations, but also by minimizing the product complexity during the design stage.Dept. of Industrial and Manufacturing Systems Engineering. Paper copy at Leddy Library: Theses & Major Papers - Basement, West Bldg. / Call Number: Thesis2006 .N33. Source: Dissertation Abstracts International, Volume: 67-07, Section: B, page: 4035. Thesis (Ph.D.)--University of Windsor (Canada), 2006

Lean Six Sigma as an enabler for Healthcare Operational Excellence in COVID-19

Purpose -This paper aims to present the results of a qualitative research interview study on the utilization and importance of Lean Six Sigma methods in the Healthcare sector in COVID-19 and in pandemics in general. Design/methodology/approach -a qualitative interview approach was utilised by interviewing leading Lean Six Sigma academics and practitioners who are expert in and have experience in Lean Six Sigma. Findings – Lean Six Sigma methods are proven and can be utilised in pandemic situations to improve efficiency and resilience in the healthcare system and readiness for pandemics. Research limitations/implications - One limitation of this research was that most of the interviewees who participated in this study come from Europe. Also, the interviews were short and at a high level. There is an opportunity for further detailed quantitative study and longitudinal case study analysis Originality - The paper provides an excellent resource to get an insight into the value of the application of Lean Six Sigma methods in pandemic situations to aid Healthcare process improvement, operational excellence and enhance public and patient safet

Reducing the delivery lead time in a food distribution SME through the implementation of six sigma methodology

Purpose – Six sigma is a systematic data driven approach to reduce the defect and improve the quality in any type of business. The purpose of this paper is to present the findings from the application of six sigma in a food service “small to medium sized enterprise” (SME) in a lean environment to reduce the waste in this field. Design/methodology/approach – A simplified version of six sigma is adopted through the application of appropriate statistical tools in order to focus on customer's requirements to identify the defect, the cause of the defect and improve the delivery process by implementing the optimum solution. Findings – The result suggests that modification in layout utilization reduced the number of causes of defect by 40 percent resulting in jumping from 1.44 sigma level to 2.09 Sigma level which is substantial improvement in SME. Research limitations/implications – Simplicity of six sigma is important to enabling any SME to identify the problem and minimize its cause through a systematic approach. Practical implications – Integrating of supply chain objectives with any quality initiatives such as lean and six sigma has a substantial effect on achieving to the targets. Originality/value – This paper represents a potential area in which six sigma methodology along side the lean management can promote supply chain management objectives for a food distribution SME

The Effect of Lean Manufacturing Tools on Waste Reduction at Arjo Didessa Sugar Factory

This study has main objective of assessment on the effects of lean manufacturing tools on waste reduction on Arjo Didesssa Sugar factory. The specific objectives of the study are from the perspective of Total productive maintenance, Mistake proofing, workplace organization (5S), continuous quality improvement and worker involvement. The research design for this study is explanatory, while the research approach is mixed approach. The target populations for this study are teams in the department of factory operation, department of kaizen and quality control. Both probability and non-probability sampling techniques are used and 208 samples selected. 188 questionnaires were completely filled and returned.  Both primary data and secondary data were used to fulfill the research objective. Quantitative part of data was analyzed by using SPSS version 20. The result of the study indicates that lean manufacturing tools are not implemented effectively therefore production waste is evident. Total productive maintenance, mistake proofing, worker involvement and continuous quality improvement have positive and significant effect on waste reduction.  Secondary data shows there is production waste in the factory but wastes are continuously reducing. Based on the evidence from questionnaire and secondary data it was concluded that lean manufacturing tools were not performed in excellent manner as result production wastes were evident in the factory. The researcher recommends based on the research findings and if lean manufacturing tools are performed in excellent manner by improving maintenance, training,  preventive and control devices for mistake proofing, Plan do check act cycle  and enhancing the skills of employees the factory they can reduce production wastes. Finally the researcher suggested for future research to be conducted by including other lean manufacturing tools to reduce production waste. Keywords: Lean Manufacturing, total productive maintenance, workplace organization (5s), mistake proofing, workers involvement, continuous quality improvemen

A Six Sigma-Based Approach to Leadership in Energy and Environmental Design for Existing Buildings: Operations and Maintenance

abstract: With increasing interest in sustainability and green building, organizations are implementing programs such as Leadership in Energy and Environmental Design for Existing Buildings: Operations and Maintenance (LEED-EB) in order to focus corporate sustainability goals on the operations of a facility and the practices of the building occupants. Green building programs help reduce the impact of a facility and bring about several environmental benefits including but not limited to energy conservation, water conservation and material conservation. In addition to various environmental benefits, green building programs can help companies become more efficient. The problem is that organizations are not always successful in their pursuits to achieve sustainability goals. It frequently take years to implement a program, and in many cases the goals for sustainability never come to fruition, when in the mean time resources are wasted, money is spent needlessly and opportunities are lost forever. This thesis addresses how the Six Sigma methodologies used by so many to implement change in their organizations could be applied to the LEED-EB program to help companies achieve sustainability results. A qualitative analysis of the Six Sigma methodologies was performed to determine if and how a LEED-EB program might utilize such methods. The two programs were found to be compatible and several areas for improvements to implementing a LEED-EB program were identified.Dissertation/ThesisM.S. Technology 201

Error Proofing In Manufacturing.

Fokus kajian ini ialah pada Jabatan Pengeluaran operasi Assembly di syarikat QSS yang mengeluarkan sistem pengestoran data luaran. This study was conducted in manufacturing environment and focused at assembly operation