Implementation of Lean Six Sigma framework with environmental considerations in an Indian automotive component manufacturing firm: a case study

2017 ◽  
Vol 28 (15) ◽  
pp. 1193-1211 ◽  
Author(s):  
R. Ben Ruben ◽  
S. Vinodh ◽  
P. Asokan
Keyword(s):  
Six Sigma ◽  
Lean Six Sigma ◽  
Manufacturing Firm ◽  
Automotive Component ◽  
Environmental Considerations ◽  
Component Manufacturing

Application of Lean Six Sigma in IT support services – a case study

2019 ◽  
Vol 31 (3) ◽  
pp. 417-435 ◽  
Author(s):  
Gijo E.V. ◽  
Jiju Antony ◽  
Vijaya Sunder M.
Keyword(s):  
Support Services ◽  
Six Sigma ◽  
Lean Six Sigma ◽  
Resolution Time ◽  
Manufacturing Firm ◽  
Content Type ◽  
It Support ◽  
System Maintenance ◽  
The Impact

Purpose Lean Six Sigma (LSS) has been accepted globally across the service sector as a management strategy for achieving process excellence. In the past one decade, the application and success of LSS in services is remarkable across Information Technology (IT) organisations. However academic research has seldom derived implications from this practitioner’s science of improving processes. The purpose of this paper is to feature the application of LSS in the system maintenance department of a manufacturing firm. Design/methodology/approach The research reported in this paper is based on a case study carried out in system maintenance department using the Six Sigma Define-Measure-Analyse-Improve-Control (DMAIC) approach and its application in reducing complaint resolution time. Findings The LSS article presented here highlights a real-world case study of how LSS DMAIC methodology help reduce the complaint resolution time from 12.5 to 8.5 h (~30 per cent improvement) and the corresponding standard deviation from 28 to 17.4 days. This study also has resulted in reducing the turn-around-time of all the core processes in the organisation. The indirect financial savings estimated as a result of this overall impact was around INR2.5m. Research limitations/implications The research was restricted to studying the impact of LSS in one organisation. The validity of the results can be improved by including more organisations and more case studies from the IT support services. Originality/value This could serve as a resource for both practitioners to derive useful implications and to academicians as it contributes to the LSS body of knowledge towards theory testing.

Deploying Lean Six Sigma framework in an automotive component manufacturing organization

2016 ◽  
Vol 7 (3) ◽  
pp. 267-293 ◽  
Author(s):  
Vikas Swarnakar ◽  
S. Vinodh
Keyword(s):  
Six Sigma ◽  
Assembly Line ◽  
Lean Six Sigma ◽  
Bottom Line ◽  
Defect Reduction ◽  
Automotive Component ◽  
Content Type ◽  
Component Manufacturing ◽  
Manufacturing Organization ◽  
Tools And Techniques

Purpose This paper aims to deploy Lean Six Sigma (LSS) framework to facilitate defect reduction and enhance bottom line results of an automotive component manufacturing organization. Design/methodology/approach LSS is a business process improvement strategy widely used in the manufacturing field for enhancing manufacturing organization performance. The integration of Lean and Six Sigma will enable the attainment of defects reduction by eliminating non-value-adding activities from production line. LSS framework has been developed with the integration of define–measure–analysis–improve–control (DMAIC) tools and techniques. Findings The finding of this study is that the LSS framework has been successfully implemented in automotive component manufacturing organization, and non-value-adding activities and defects from assembly line have been reduced. The proposed LSS framework applies lean tools within Six Sigma DMAIC approach to facilitate waste elimination and defect reduction. The developed framework with linkage of DMAIC tools and techniques reduces defects and non-value-adding activities with enhanced bottom line results. The implementation of proposed LSS framework shows effective improvement in key metrics. Research limitations/implications The developed framework has been test implemented in an automotive component manufacturing organization. In future, more number of studies could be conducted. Further, advanced lean tools and techniques could be included in the framework for increasing the effectiveness of production line. Practical implications The proposed LSS framework with linkage of DMAIC tools and techniques has been successfully implemented in an assembly line of automotive component manufacturing organization. This method is presently applied for an automotive component manufacturing organization; in future, the approach could be applied in different industrial sectors with addition of new tools and techniques for improving its effectiveness. Originality/value LSS framework has been designed and test implemented in an assembly line of an automotive component manufacturing organization. Hence, the inferences are practical and key results of the study.

scholarly journals A Lean Six Sigma framework to enhance the competitiveness in selected automotive component manufacturing organisations

2018 ◽  
Vol 21 (1) ◽  
Author(s):  
Raveen Rathilall ◽  
Shalini Singh
Keyword(s):  
Six Sigma ◽  
Quantitative Methods ◽  
Target Population ◽  
Lean Six Sigma ◽  
Management Style ◽  
Automotive Component ◽  
The World ◽  
The Status ◽  
Component Manufacturing ◽  
Six Sigma Approach

Background: Currently, globalisation, economic uncertainty and fluctuating market demands prompt leaders all over the world to improve their operations and to enhance innovations in processes, products and services in a very reactive manner. Literature shows that the adoption of an integrated Lean Six Sigma tool can assist them to compete with the rest of the world in a manner where productivity, quality and operational costs reduction are crucial for economic success. Aim: This article investigates the integration of Lean and Six Sigma tools as a unified approach to continuous improvement and develops a Lean Six Sigma framework for selected automotive component manufacturing organisations in KwaZulu-Natal (KZN), South Africa. Method: The quantitative methods of research were adopted. The target population (42) was organisations within the Durban Automotive Cluster of which five were used for the pilot work. An empirical study was conducted using a survey questionnaire in measurable format to gather practical information from the sample organisations on the status of their existing business improvement programmes and quality practices. Results: The results of the study demonstratedthat the organisations had a very low success rate of Lean and Six Sigma adoption as standalone systems, as they found it difficult to maintain the transition from theory to practice. Conclusion: Hence the adoption of an integrated Lean Six Sigma approach was absent and it can be concluded that the proposed Lean Six Sigma framework affords the KZN automotive sector a unique opportunity to integrate and operate with both tools of quality that complement its management style and industry demands.

scholarly journals Productivity and process performance in a manual trimming cell exploiting Lean Six Sigma (LSS) DMAIC – a case study in laminated panel production

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Daniel Lee Hardy ◽  
Saikat Kundu ◽  
Muhammad Latif
Keyword(s):  
Six Sigma ◽  
Lean Manufacturing ◽  
Lean Six Sigma ◽  
Process Performance ◽  
Content Type ◽  
Intermittent Feeding ◽  
Staff Members ◽  
Component Manufacturing ◽  
Production Cell

PurposeThe purpose of this case study is to investigate inefficiency and downtime factors within a panel lamination process cell at a timber component manufacturing company. Areas of concern related predominantly to the manual trimming or finishing of a range of laminated timber panels for the caravan and leisure industry. The intermittent feeding of inputs and material outputs was also investigated during this case study.Design/methodology/approachThe case study was conducted over a six-month period using the Six Sigma defining, measuring, analysing, improving and controlling (DMAIC) construct. But was equally supported through a combination of tools both applied in lean manufacturing and statistical properties commonly assigned to Six Sigma projects.FindingsThis paper provides insights about the identification of the root causes for poor productivity and overall equipment effectiveness issues experienced by manual trimming/finishing operations in a laminated timber panel production cell. It also identifies solutions to overcome these issues and benefits (such as improved OEE, reduced downtime and savings in staffing costs) that were obtained due to the application of these solutions. This study contributes to understanding the interconnections of fork-lift truck movements with staff members working within manual finishing areas connected to a panel lamination cell.Originality/valueThis paper contributes new knowledge into the root causes of poor productivity and process performance within manual finishing operations in a laminated timber panel production cell at a small medium enterprise. By applying elements of Six Sigma' quality focussed analytical methods within the DMAIC structure, and simultaneously applying the waste reduction method of lean manufacturing, this paper provides useful perspective on why both these quality improvement-based ideologies are applied to overcome process issues in manufacturing.

Lean Six Sigma project selection using hybrid approach based on fuzzy DEMATEL–ANP–TOPSIS

2015 ◽  
Vol 6 (4) ◽  
pp. 313-338 ◽  
Author(s):  
S Vinodh ◽  
Vikas Swarnakar
Keyword(s):  
Decision Making ◽  
Six Sigma ◽  
Hybrid Approach ◽  
Project Selection ◽  
Lean Six Sigma ◽  
Automotive Component ◽  
Content Type ◽  
Industrial Sectors ◽  
Component Manufacturing ◽  
Manufacturing Organization

Purpose – The purpose of this paper is to select the optimal Lean Six Sigma (LSS) project using hybrid fuzzy-based Multi-Criteria Decision-Making (MCDM) approach for an automotive component manufacturing organization. Design/methodology/approach – The LSS project selection has been formulated as the MCDM problem. Hybrid MCDM method based on Decision-Making Trial and Evaluation Laboratory Model (DEMATEL), Analytical Network Process (ANP) and Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) has been used to select the optimal LSS project. The methodology enabled the practitioners to systematically prioritize LSS projects. Findings – The finding of this study is that, out of five LSS projects, project P3 is the best LSS project. P3 is the optimal LSS project with reduced failure risk, and efforts are being taken to implement the selected project. Research limitations/implications – The problem formulation and methodology has been tested for a single study. In future, more number of studies could be conducted using the hybrid approach. This method is presently applied for an automotive component manufacturing organization; in future, the approach could be applied in different industrial sectors for improving its effectiveness. Practical implications – The case study has been conducted in a real-time industrial problem. The practitioners expressed the usefulness of the methodology for prioritizing LSS projects Hence, the inferences derived are found to possess practical relevance. Originality/value – The original contribution of the study is the selection of optimal LSS project using hybrid MCDM technique.

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