Application of Lean Six Sigma framework for improving manufacturing efficiency: a case study in Indian context

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Astha Sharma ◽  
Neeraj Bhanot ◽  
Ajay Gupta ◽  
Rajeev Trehan
Keyword(s):  
Simulation Model ◽  
Six Sigma ◽  
Production Line ◽  
Manufacturing Industry ◽  
Lean Six Sigma ◽  
Expected Improvement ◽  
Batch Size ◽  
Value Stream Mapping ◽  
Content Type ◽  
Value Stream

PurposeThis study aims to utilize DMAIC methodology along with value stream mapping and other Lean Six Sigma tools in a major automobile light manufacturing industry to reduce defect rates and increase production capacity in their manufacturing line. The study also proposes a modified framework based on lean principles and FlexSim to identify and reduce waste in the selected industry.Design/methodology/approachA Lean Six Sigma modified framework has been deployed with DMAIC to reduce the defect rate and increase the production rate. Various tools like value stream mapping, brainstorming, Pareto charts, 5S, kanban, etc. have been used at different phases of DMAIC targeting wastes and inventory in the production line. Also, a simulation model has been utilized for the automobile light manufacturing industry to improve the machine utilization time with varying batch sizes.FindingsThe results of the study indicated a 53% reduction in defect rates. Thus, there would be an expected improvement in sigma value from 3.78 to 3.89 and a reduction in defects per million opportunities (DPMO) from 11,244 to 8,493. Additionally, simulation model using FlexSim was developed, and the optimum ordering batch size of raw material was obtained. It was also analyzed that idle time for various stations could be reduced by up to 30%.Practical implicationsThe utilized framework helps identify defects for managers to increase production efficiency. The workers, operators and supervisors on the production line also need to be trained regularly for identifying the areas of improvement.Originality/valueThe modified Lean Six Sigma framework used in this study includes FlexSim simulation to make the framework robust, which has not been used with LSS tools in the literature studied. Also, the LSS finds very less application in the manufacturing domain, considering which this study tends to add value in existing literature taking a case of an automobile light manufacturing industry.

Managing industrial operations by lean thinking using value stream mapping and six sigma in manufacturing unit

2019 ◽  
Vol 58 (6) ◽  
pp. 1118-1148 ◽  
Author(s):  
Jagdeep Singh ◽  
Harwinder Singh ◽  
Amandeep Singh ◽  
Jashanpreet Singh
Keyword(s):  
Six Sigma ◽  
Lean Manufacturing ◽  
Lead Time ◽  
Manufacturing Industry ◽  
Value Stream Mapping ◽  
Lean Thinking ◽  
Content Type ◽  
Value Stream ◽  
Future State ◽  
Industrial Operations

Purpose The purpose of this paper is to cover the significance of lean thinking using value stream mapping and six sigma methodology in managing industrial operations. Design/methodology/approach Lean manufacturing is an efficient approach for identifying and eliminating waste through a continuous improvement via flow of the product/service at the pull of customer in chase of exactness. This study has been carried out in a manufacturing unit of Northern India that was suffering from high production lead time and work in progress (WIP) inventory. Findings The current state and future state maps for the critical product have been prepared. On comparison of both current and future state maps, it was observed that lead time has been reduced by 14.88 percent, processing time by 14.71 percent and wastage of material movement by 37.97 percent. As proposed in model, the WIP inventories have been reduced by 17.76 percent and workforce by 17.64 percent. Further it would lead to the profit of Rs161,800 per annum. Six sigma projects have been carried out to reduce rejections of the critical product P-19 under study. The total length of the product was undersize of the critical product. Root cause analysis technique has been used through strategic DMAIC implementation. Results of investigation demonstrated net savings of rupees 145,560 annually. Originality/value The paper demonstrates the practical application of lean thinking, showing how it can bring real breakthroughs in saving cost in the manufacturing industry.

Development of sustainable value stream mapping (SVSM) for unit part manufacturing

2019 ◽  
Vol 11 (3) ◽  
pp. 493-514 ◽  
Author(s):  
Aatish Kumar Mishra ◽  
Ayush Sharma ◽  
Moraldeepsingh Sachdeo ◽  
Jayakrishna K.
Keyword(s):  
Manufacturing Industry ◽  
Main Tool ◽  
Organizational Level ◽  
Value Stream Mapping ◽  
Simulation Approach ◽  
Content Type ◽  
Study Approach ◽  
Value Stream ◽  
Sustainable Value

Purpose The main purpose of this paper is to analyze the current state of a bonnet-manufacturing industry and to optimize the process by designing a future state map using simulation approach. Design/methodology/approach The case study approach has been proposed to highlight the applicability of value stream mapping (VSM) in an Indian bonnet manufacturing organization. The methodology used relies on formulation of VSM being the main tool used to identify the opportunities for classifying and eliminating bottlenecks with the help of various lean techniques. A contrast of present and past scenarios is highlighted to underscore the importance of using VSM with ARENA simulation. Findings Application of the proposed simulation approach has helped the organization reduce the cycle time significantly by 30 per cent over the entire production time. The average number of work-in-progress pieces has also decreased by about ten. In addition, enhancements have been seen with respect to ecological parameters, e.g. carbon footprint has been reduced to 83.7 percent across the process. Research limitations/implications The proposed approach of using a simulation-based VSM helps in reducing the time involved in traditional VSM method. This approach is also easy to implement at any organizational level. Practical implications It is believed that this paper will aid not just industrialists but also academic professionals to appreciate the role of simulation using ARENA in helping them understand how to attack the various problems faced by industries. The results of the study indicate that by applying this methodology, there will be a reduction not only in cost but also in environmental impacts. Originality/value The paper incorporates a real case study, which shows application of VSM for implementing lean principles in a bonnet-manufacturing industry. Break-even analysis presented fills the gap which previous literatures have been missing.

Lean Six Sigma: a clinical treatment for the recovery of Indian manufacturing sector from the after-effects of coronavirus

2020 ◽  
Vol 17 (3) ◽  
pp. 311-322 ◽  
Author(s):  
Harsimran Singh Sodhi
Keyword(s):  
Six Sigma ◽  
Manufacturing Industry ◽  
Manufacturing Sector ◽  
Lean Six Sigma ◽  
Clinical Treatment ◽  
Content Type ◽  
After Effects ◽  
The World ◽  
Tools And Techniques ◽  
The Impact

PurposeManufacturing industry is quite badly hit due to the coronavirus. Manufacturing has been stopped in every country. The present study will provide assistance to the practitioners to recover manufacturing sector from the after-effects of coronavirus.Design/methodology/approachA thorough review of the recent articles published in the newspaper and web has been done to make a viewpoint on the global industrial impact due to epidemic corona. Reports of WHO, IMF, World Bank, RBI and so forth are also reviewed. Further, Lean Six Sigma has been suggested which can be implemented to recover manufacturing industry from the ill effects of corona.FindingsIn present study the problem causd in the manufacturing sector due to corona virus has been identified and a clinical treatment for the same has been proposed by using the tools and techniques of Lean Six Sigma.Originality/valueThe impact of coronavirus has become a huge issue not only for the physical health of human beings but also for the economic health of most of the countries in the world, as it is pushing the world economy toward huge economic depression. Therefore, it becomes the moral responsibility of industrial experts to suggest the tools and techniques to the manufacturing industry for faster recovery.

scholarly journals LEAN SIX SIGMA: MULTIPLE CASE STUDY

2018 ◽  
Vol 9 (1) ◽  
pp. 74
Author(s):  
Orlando Roque Da Silva ◽  
Alessandro Marco Rosini ◽  
Arnoldo J H Guevara ◽  
Angelo Palmisano ◽  
Delvio Venanzi
Keyword(s):  
Six Sigma ◽  
Lean Manufacturing ◽  
Lean Six Sigma ◽  
Value Stream Mapping ◽  
Exploratory Research ◽  
Value Stream ◽  
Multiple Case ◽  
Mapping Techniques ◽  
And Control

Lean Six Sigma is a management focused on quality and productive performance in operating systems. This article discusses the foundations of this methodology through of two different conceptions of management, Lean Manufacturing and Six Sigma. First of the article explain the DMAIC (define measure, analyze, improve and control) and their respective phases, after the Lean philosophy with the sipoc and value stream mapping techniques. The article aims to show integration of these two conception and their results. The methodology consisted in a theory was based on a literature search an exploratory research which consisted of three case studies in differences companies located in Sorocaba, São Paulo. In this article studies the applying of Lean Six Sigma and its results.

scholarly journals Logistics services and Lean Six Sigma implementation: a case study

2016 ◽  
Vol 7 (3) ◽  
pp. 324-342 ◽  
Author(s):  
Leopoldo Gutierrez-Gutierrez ◽  
Sander de Leeuw ◽  
Ruud Dubbers
Keyword(s):  
Six Sigma ◽  
Process Management ◽  
Relevant Information ◽  
Lean Six Sigma ◽  
Consumer Electronics ◽  
Value Stream Mapping ◽  
Content Type ◽  
Control Approach ◽  
Logistics Services

Purpose This paper aims to analyze the application of Lean Six Sigma (LSS) framework for supporting continuous improvement (CI) in logistics services. Both the lean philosophy and the Six Sigma methodology have become two of the most important initiatives for CI in organizations. The combination of both alternatives – LSS – brings significant benefits for companies applying this method, and its influence in logistics services can be relevant. Design/methodology/approach A case study on the logistics services of a large consumer electronics company is performed. In this sector, high quality in logistics services is crucial. Using within-case and cross-case analyses, the paper discusses the implementation of LSS in two internal logistics processes. Findings The paper identifies important implementation aspects when applying LSS to logistics services, such as CI structure, strategic analysis, cross-functional teams and process management. Furthermore, the paper discusses the potential in logistics services of the DMAIC (define, measure, analyze, improve and control) approach and tools such as value stream mapping, SIPOC (supplier, input, process, output, and customer) and process mapping. Practical implications The paper analyzes two logistics processes where LSS has been applied – a payment process and a request-to-ship process. The analysis of both processes offers relevant information about organizational implementation in a logistics services environment about process improvement and about the use of LSS tools. Originality/value First, this paper addresses the gap in literature about LSS and logistics’ activities. Furthermore, the case company, with more than 9,000 employees and distributing its products to more than 100 countries, constitutes a valuable source of information to obtain insights into the implications of implementing LSS in logistics services.

Experiencing Lean Six Sigma in the French residential construction

2016 ◽  
Vol 7 (4) ◽  
pp. 346-368 ◽  
Author(s):  
Zakaria Dakhli ◽  
Zoubeir Lafhaj ◽  
Antoine Bos
Keyword(s):  
Real Estate ◽  
Information Flow ◽  
Six Sigma ◽  
Manufacturing Industry ◽  
Lean Six Sigma ◽  
Real Estate Development ◽  
Content Type ◽  
Real Value ◽  
Practical Implications ◽  
Practical Recommendations

Purpose Compared to the manufacturing industry, Lean Six Sigma (LSS) lacks a clear methodology for its application in the tertiary service. One reason is the difficulties to assess information flow compared to physical flow. Indeed, the use of information flow as a process entry in the LSS method is not well investigated, mainly due to the difficulties in collecting adequate and sufficient data. The purpose of this research study is to investigate the application of LSS in the tertiary service, in particular, real estate development. Design/methodology/approach The paper is based on an action research methodology where LSS methodology is applied to solve client-dissatisfaction issue. One of its main causes is found to be the late delivery time. The work describes how the method was applied. Findings LSS is an adequate approach for making well-thought-out improvement in real estate development. Practical implications The work provides an implementation of LSS in real estate development. It also gives new insights into the LSS application in the tertiary service. The work also suggests practical recommendations and solutions to address the main challenges faced by real estate development. Originality/value Construction is governed by many processes that are difficult to identify and, even more, to assess. LSS helps identifying those which create real value for the client.

scholarly journals IMPLEMENTASI METODE LEAN SIX SIGMA PADA PRODUKSI WAJAN NOMOR 18 DI CV. XYZ

2019 ◽  
Vol 8 (2) ◽  
Author(s):  
Siti Hardianti, Neva Satyahadewi, Nurfitri Imro’ah
Keyword(s):  
Failure Mode ◽  
Six Sigma ◽  
Lean Six Sigma ◽  
Value Stream Mapping ◽  
Risk Priority Number ◽  
Value Stream

Pengendalian kualitas dapat dilakukan dengan berbagai cara, diantaranya menggunakan metode Lean Six Sigma. Metode Lean Six Sigma dapat menunjukkan jalannya proses produksi sehingga diketahui pemborosan, kecacatan dan proses terjadinya produksi melalui value stream mapping. Lean Six Sigma dapat diterapkan di bidang industri, satu diantaranya adalah perusahaan CV. XYZ. Perusahaan tersebut memproduksi wajan dengan nomor 10, 11, 12, 13, 14, 15, 16, 18, 20, 22, 24, 26, 28 dan 30. Wajan nomor 18 adalah wajan yang paling diminati konsumen. Tahapan dalam Lean Six Sigma dimulai dari define, measure dan analyze. Jenis kecacatan diklasifikasikan menjadi empat kelas yaitu sangat serius (A), serius (B), cukup serius (C) dan tidak serius (D) dengan jumlah observasi sebanyak 78 hari. Kecacatan terbesar terjadi di kelas cacat sangat serius yaitu sebesar 44,38%. Level sigma merupakan kemungkinan besar kecacatan yang akan terjadi jika memproduksi satu juta produk. Pada penelitian ini, level sigma yang dihasilkan kecacatan sangat serius adalah 3,2, sehingga dengan menggunakan nilai Defect Per Million Oppertunities (DPMO) dapat disimpulkan bahwa dalam satu juta produksi kemungkinan produk cacat sebesar 44.211 buah. Berdasarkan analisis Failure Mode and Effect Analyze (FMEA), diketahui penyebab kecacatan sangat serius dikarenakan material dengan nilai Risk Priority Number (RPN) sebesar 84. Sehingga dengan menggunakan kriteria penilaian RPN diketahui bahwa kecacatan yang disebabkan oleh material tergolong sedang.  Kata Kunci: Demerit, Failure Mode and Effect Analyze. 

Research on production process optimization of precast concrete component factory based on value stream mapping

2019 ◽  
Vol 27 (4) ◽  
pp. 850-871 ◽  
Author(s):  
Shuqiang Wang ◽  
Jia Tang ◽  
Yiquan Zou ◽  
Qihui Zhou
Keyword(s):  
Production Process ◽  
Process Optimization ◽  
Production Line ◽  
Precast Concrete ◽  
Value Stream Mapping ◽  
Content Type ◽  
Value Stream ◽  
Current Value ◽  
Concrete Component ◽  
Component Production

Purpose The purpose of this paper is to investigate the process optimization of a precast concrete component production line by using value stream mapping. Design/methodology/approach This paper is an empirical focused on of lean production theory and value stream mapping. The data in the case study were collected in real time on-site for each process during the production process of a prefabricated exterior wall. Findings The results of the current value stream map indicate that the main problems of the current production process are related to equipment, technology and organization. The equipment problems include simple demolding and cleaning tools and the lack of professional transfer channels. The technology problems include the lack of a marking mechanism and pipeline exit mechanism. There is a lack of standard operating procedures and incomplete process convergence. A comparison and analysis of the current value stream and the future value flow indicate that optimizations of the process flow, the production line layout, and the standard operating procedures have shortened the delivery cycle, reduced the number of workers, improved the operator’s operating level and balanced the production line. Practical implications The results of this study provide practitioners with a clear understanding of the optimization of the precast concrete component production and represent a method and basis for the process optimization of a factory production line; the approach is suitable for process optimization in other areas. Originality/value This research represents an innovative application of lean production theory and value stream mapping in a complex production line of precast concrete components and thereby fills the gap between the theory and practice of the optimization of a precast concrete component production line.

Evaluation of value stream mapping (VSM) applicability to the oil and gas chain processes

2018 ◽  
Vol 11 (2) ◽  
pp. 309-330 ◽  
Author(s):  
Cicero Vasconcelos Ferreira Lobo ◽  
Robisom Damasceno Calado ◽  
Roberta Dalvo Pereira da Conceição
Keyword(s):  
Manufacturing Industry ◽  
Oil And Gas ◽  
Value Stream Mapping ◽  
Content Type ◽  
Value Stream ◽  
Chain Processes ◽  
Analysis Methodology ◽  
Research Gap ◽  
Scopus Database ◽  
Conference Papers

Purpose Lean approach has overcome the boundaries of the automotive and manufacturing industry and has achieved many different sectors of the economy, including services. In this context, this paper aims to investigate the applicability of value stream mapping (VSM) tool in processes of the oil and gas chain. Also, this paper investigates if there is a specific framework currently being used by organizations belonging to this chain to map the value stream of its processes. Design/methodology/approach A detailed systematic review of the literature is done by using a set of relevant keywords based on peer-reviewed journal articles and conference papers available in the Scopus database, analyzing data from 2012 to 2017. Content analysis methodology involving a four-step process (identification, screening, eligibility and inclusion) suggested by Moher et al. (2009) was adopted for this study. Findings The number of studies in literature on VSM applicability to the oil and gas chain processes is low when compared to studies regarding the application of lean tools and methods in general in this area. Also, there is no specific framework that has been used by the oil and gas chain companies to carry out the VSM, which is a research gap that can be further explored. Research limitations/implications Sample size for this research consists of 42 studies, thereby limiting the generalizability of the research studies. However, the analysis presented in this paper was based only on Scopus database, which is a remarkable and broad base, which provided robustness to the data found. Practical implications Practicing managers of oil and gas chain who are planning to transform their processes can use the VSM for it. Researchers can explore the research gap found in this study and develop a specific framework to implement VSM in the oil and gas chain processes. Originality/value This is the first paper to evaluate the VSM tool applicability to the oil and gas chain processes based on an systematic literature review and understand if this is possible and if there is a specific framework to carry out this task.

Empirical assessment of the future adequacy of value stream mapping in manufacturing industries

2018 ◽  
Vol 29 (5) ◽  
pp. 886-906 ◽  
Author(s):  
Andreas Lugert ◽  
Aglaya Batz ◽  
Herwig Winkler
Keyword(s):  
Industry 4.0 ◽  
Manufacturing Industry ◽  
Point Of View ◽  
Current Status ◽  
Value Stream Mapping ◽  
Content Type ◽  
Empirical Survey ◽  
Value Stream ◽  
Research Activities ◽  
The Impact

Purpose Value stream mapping (VSM) is very common in the manufacturing industry to enhance transparency and support improvements within the production process. The purpose of this paper is to evaluate the current status of the method from the user’s point of view and addresses its future sustainability in the context of the ongoing digitalization. Design/methodology/approach An empirical survey with 170 participants from different branches was conducted. The web-based questionnaire covers the topics Lean Management, respectively, VSM, Industry 4.0, the integration of both approaches as well as a possible need for action to modify the VSM. Results are analyzed in a quantitative way. Findings Benefits and shortcomings of VSM are already confirmed by previous publications. The serious challenge is the lack of flexibility of the method. In general users appreciate a combination of Lean methods and solutions of Industry 4.0. Moreover 92 percent of the participating experts request further development of the VSM using digitalization to compensate weaknesses. Research limitations/implications The findings are based only on Lean expert’s opinion. Over 95 percent of the participants are from Europe however most of them are from Germany. Although the results are adequate an international expansion of the survey would be advisable in order to distinguish local differences and similarities. In future work researchers need to further develop VSM to overcome the identified gaps. Practical implications Results of the study indicate the viewpoint of experts within different branches. This enables users to undertake a self-assessment regarding their own VSM-estimation. Originality/value This paper provides a current evaluation of the VSM from an exploratory perspective. The impact of global trends and new opportunities facilitated by digitalization are considered. Shortcomings and fields of actions become clear. Based on that necessity further research activities can be designed.

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