Integrating Ergonomics with Lean Six Sigma on a meal solutions industrial kitchen

The integration of Ergonomics with Lean and Six Sigma are the foundations of this dissertation. Lean Six Sigma (LSS) philosophy has already proven its worth through several successful implementations in the most varied kind of industry. Several researchers are complementing Lean Six Sigma values and prepositions with other disciplines, so that improvement doesn’t concern only the processes flow, but also the entire ecosystem with it. Therefore, Ergonomics integrates perfectly with LSS, not only in a sense of concerning about employees while LSS concerns about processes, but also helping to improve efficiency. It should be integrated on the core of every company’s management team. This dissertation focuses on studying the production system of an Industrial Kitchen which produces ready-to-eat (RTE) meals for Pingo Doce retailer. The aim was to apply Ergonomics, Lean and Six Sigma’s principles in an integrated form, in order to improve the Kitchen’s productivity and efficiency. The HACCP standards are crucial in a food industry of this kind so were, therefore, considered at all times. The methodology utilized was a holistic approach of the DMAIC cycle, including Ergonomics in all stages and HACCP especially in the Improve phase. This case study brought added value to the company by achieving the initially proposed goals, regarding elimination of waste and productivity increase by 16% in 2015 vs 2014 results, always focusing on the well-being of employees. The operational costs decreased 18%, overcoming the initially set goal of 6%. Developing this project has made it possible to understand the applicability of the utilized methodology and the impact it may have in all kinds of industries, as well as its limitations. The DMAIC cycle, together with all the other LSS implemented tools, proved their worth when it comes to planning and implementing a project of this kind. They are simple to apply and highly effective. The approached theme – and the integration of other disciplines with LSS – should be applied in different industries, so that broader conclusions can be made while continuously improving the implementation strategy and proving its value

Green Lean Six Sigma for improving manufacturing sustainability: Framework development and validation

In the past few decades, a competitive landscape, learned customers and rigorous regulations have forced manufacturing industries to focus on sustainability alongside operational efficiency. The main objective of the present study is to develop a systematic Green Lean Six Sigma (GLSS) framework for improvement in operational efficiency together with environmental and social sustainability. Further, the proposed framework was tested in a leading manufacturing company. The framework was designed with insights gained from the literature and industrial personnel and encompasses the systematic application of different tools of the Green paradigm, Lean, and Six Sigma, from the identification and assessment of the problem to the sustainment of the adopted measures. A systematic application of lifecycle assessment and social lifecycle assessment was used to assess environmental and societal performance. The sustainability focused GLSS framework enhances the environmental capability, process performance and provides a new perspective for researchers and practitioners to support GLSS projects to achieving higher sustainability dynamics

Set up time Reduction and Quality Improvement on the Shop floor using different lean and quality tools

The purpose of this thesis document is to describe a method developed for reducing setup time in machining processes and simultaneously improve the quality of production after setup. Bosch Rexroth at Fountain Inn is a semi-automated plant and is still in its initial stages of standardizing the setup process. Setup time at different machining centers includes: machining time, inspection time, loading and unloading times and deburring. The focus of the described method is in reducing setup times related to inspection time and loading and unloading times. To achieve success in these problems the following new tools were developed: first piece inspection charts, design inspection fixture and design of new handling tools. This work involved interaction with operators, collection of data, and analyzing and developing new plans based on the analysis. Tools like Failure Modes Effects Analysis (FMEA), 5S and Single-Minute Exchange of Die (SMED) techniques helped in making and implementing these changes on the production line. Implementation of first piece inspection charts and inspection reduced inspection time by almost 50%. Design of handling tools helped in reducing stress on the operator and also in reducing loading and unloading time by 40%. Also quality was improved through a related project. This subproject\u27s aim is to reduce shaft alignment problems as reported by the customer. To achieve this goal I designed a fully automatic shaft alignment tool, which helps operator in installing the shaft into the pump without any difficulty. This shaft alignment tool is installed on the line and eliminated the shaft alignment problems completely. Also the quality improvement techniques and set up time reduction techniques used at BOSCH are discussed in this documen

Sound absorption of lightweight brick containing expanded polystyrene beads and palm oil fuel ash

Bricks are considered as important and strongest materials being used over the years. Commonly, bricks are made of clay mineral and usually used in construction of building wall. The purpose of this study is to assess the effectiveness of palm oil fuel ash (POFA) and expanded polystyrene beads (EPS) as a brick and its suitability as sound absorption material. POFA is used as partial replacement of cement while EPS as partial replacement of sand in the mortar mixture. Various percentages of EPS and POFA have been used which include 0%, 20%, 30%, 40% and 50% as sand replacement and from 0%, 5%, 10%, 15%, 20% and 25% as cement replacement respectively. Sound absorption tests were conducted using impedance tube. From this study, it has been identified that for sound absorption test, lowest result recorded is at maximum 25% POFA replacement with 50% EPS replacement with 0.011 sound absorption coefficient at frequency of 3500 Hz. The best sound absorption coefficient recorded is 0.998 at frequency of 250 Hz for sample with 0% EPS and 20% POFA replacement. It can be recognized that the brick produced have the excellent sound absorption

Improve the productivity of rubber bushings in a rubber moulding company by applying the Lean Principle

The rubber moulding manufacturing businesses are facing problems to fulfil the customer requirements and stay competitive with the global players in terms of cost, quality and services. Some of the notable rubber moulding industries are unable to meet the customer requirements in the aspect of delivery time and demand. One of the reasons why most of the rubber moulding manufacturing companies are still unable to implement lean manufacturing systems due to a lack of knowledge and information. The drive for yearly cost savings from automotive customers has driven suppliers to research ways to improve production efficiency and raise production. Companies are continuously searching for new instruments to optimise manufacturing processes, which provide considerable increases in productivity, savings and customer satisfaction. This study aims to reduce waste and increase the productivity of the rubber moulding manufacturing process by using the Lean principles, which can help identify waste from information flow, material flow, and process flow. In this study, lean principles with the support of the Ishikawa Diagram were able to find the highest cessation process that contributed to non-value-added activities in rubber production. Finishing processes, which have the highest process steps selected for improvement study. The study shows that productivity increased by implementing the cellular manufacturing principles. A complete process step can be reduced from 22.5 hours to 0.5 hours in the Finishing process. (Abstract by author

Lean Six Sigma in Manufacturing: A Comprehensive Review

Lean Six Sigma is a systematic approach to reduce or eliminate activities that do not add value to the process. It highlights removing wasteful steps in a process and taking the only value added steps. The lean six sigma method ensures high quality and customer satisfaction in the manufacturing. The main purpose of this chapter is to explore the Lean Six Sigma (LSS) in the manufacturing sector. This chapter focuses on the different critical aspects of LSS. The core sections of this chapter are Introduction; Key lean six sigma principles; Tools and techniques; Lean six sigma methodologies; Critical success factors; Lean six sigma framework; Lean six sigma strategy; Implementation of Lean Six Sigma in SMEs; significant benefits; Significant barriers to implement lean; Assessment of Lean Six Sigma Readiness; Emerging trends in Lean Six Sigma; and Successful examples/stories in the manufacturing industry. The final section of the chapter contains the conclusions and suggestions. It is important for practitioners to be aware of Lean six sigma benefits, impeding factors, Tools and techniques, methodologies etc. before starting the Lean six sigma implementation process. Hence, this chapter could provide valuable insights to practitioners. It also gives an opportunity to Lean six sigma researchers to understand some common themes within this chapter in depth

Lean Analysis Framework for Waste Management: A Case of Indonesian Textile Company

This study aims to propose a lean analysis framework for waste management and to test it into the field case. The proposed framework was applied in a weaving process of a textile company in Indonesia. The seven classical Lean wastes were identified using value stream mapping (VSM). The result was then analyzed using the waste assessment model within which waste relationship matrix (WRM) and waste assessment questionnaire (WAQ) according to the answers of the head of weaving division studied. The major source of wastes was then determined utilizing the value stream analysis tool (VALSAT). In order to thoroughly examine the root cause of such dominant wastes and to propose corrective plans to minimize the waste, a fishbone diagram was used. As the main result, this study provides a lean waste analysis framework with examples to orientate managers about wastes. Particularly in our specific case, the results demonstrate that the waiting and defect become the most significant wastes that need to be treated. These findings allow a company to organize its activities and select tools or practices to optimize its efforts to create proper corrective plans in eliminating waste. In our study, the plans include periodic maintenance of weaving machines, clear division of tasks on the distribution of weft yarns, and eliminating unnecessary activities. In addition, it is mandatory to ensure the quality of warp yarns delivered to the weaving process as well as to perform a periodic calibration of equipment on weaving machines. This study advances in the theoretical and practical field by showing a structured way to incorporate lean analysis that can be adopted for any organization

Enhance quality improvement through lean six sigma in division Side Board Clavinova Piano's

[EN] A lean production system is one of the main factors that every company must have to improve quality, especially reducing waste that occurs in the production line. The musical instrument industry such as Piano manufacturing includes industries that reduce waste by improving the manufacturing system. The company s strategy to eliminate this waste is to create an effective and efficient work system. The piano production process still has several problems, such as the presence of waste. This is an obstacle in improving the quality of production by reducing the waste that occurs. For this reason, this research focuses on improving the quality of production by reducing waste that occurs, finding the cause of the problem and taking corrective action. The method used in this research is the integration of Lean and Six Sigma and the DMAIC framework. The process is waste flow and production problems are identified in Define phase and residual measurement is measured in Measurement phase. Fishbone diagrams and the application of FMEA are used to analyze the factors that cause problems that occur and prioritize improvements to solve these problems. The implementation of Value Stream Mapping (VSM) is applied to the Enhance of quality improvement phase to reduce waste. The results showed that product quality increased from an average sigma level of 3.53 to 3.79 where overproduction decreased by 41% and Side Board production leadtime decreased by 373 second.Hernadewita, H.; Setiawan, I.; Hendra, H. (2022). Enhance quality improvement through lean six sigma in division Side Board Clavinova Piano's. International Journal of Production Management and Engineering. 10(2):173-181. https://doi.org/10.4995/ijpme.2022.16140OJS17318110

Implementation of lean manufacturing to enhance the efficiency of acrylic resins production process

High lead time processing of acrylic resins leads to the production of products to consumer undergoes and high-production costs. This study aims to reduce lead time by analyzing various activities that have value added, non value added, and necessary non value added. The research is conducted using lean manufacturing approaches on acrylic resin production processes. The analysis shows that the activity of delay and transportation is a contributor of waste that occurs in the production process of acrylic resins. Improvements by minimizing both activities in the are thining tank, reactor, and monomer tank can increase the efficiency of the production process. The improvement results show a decrease in lead time from 1298 minutes to 1075 minutes. This study demonstrates that lean manufacturing can improve the time process efficiency of 17.18%, which means the output ratio will increase by around 17.18% in a process.High lead time processing of acrylic resins leads to the production of products to consumer undergoes and high-production costs. This study aims to reduce lead time by analyzing various activities that have value-added, non-value-added, and necessary non-value-added. The research is conducted using lean manufacturing approaches on acrylic resin production processes. The analysis shows that the activity of delay and transportation is a contributor of waste that occurs in the production process of acrylic resins. Improvements by minimizing both activities in the are thining tank, reactor, and monomer tank can increase the efficiency of the production process. The improvement results show a decrease in lead time from 1298 minutes to 1075 minutes. This study demonstrates that lean manufacturing can improve the time process efficiency of 17.18%, which means the output ratio will increase by around 17.18% in a process