scholarly journals Analisis Pengurangan Non-Value Added Activities dengan Metode Lean Six Sigma

2020 ◽  
Vol 2 (2) ◽  
pp. 63
Author(s):  
Iis Azelya ◽  
Gesit Thabrani
Keyword(s):  
Six Sigma ◽  
Value Added ◽  
Medical Personnel ◽  
Lean Six Sigma ◽  
Value Stream Mapping ◽  
Contributing Factors ◽  
Value Stream ◽  
Outpatient Unit ◽  
Fishbone Diagram ◽  
Time Required

Purpose - This study was conducted with the intention to find out what is included as non-value added activity that is happened in patient’s flow and how to reduce it using lean six sigma method in outpatient department of regional public hospital of Kerinci M.H A Thalib.Methodology - This research uses lean six sigma method with analysis tools in the form of value stream mapping and fishbone diagrams in order to reduce the activities identified as non value added in the outpatient units of the M. H A Thalib general hospital in Kerinci Regency.Finding - The results of the study showed that the lead time required in the flow of patients in this outpatient unit is 7300.27 seconds with a percentage of Process Cycle Efficiency is only 12.22%, and contributing factors such as databases that are not used effectively, delays in medical personnel, lack of infrastructure, and so on. Keywords: Lean Six Sigma, Value Stream Mapping, Fishbone Diagram, DMAIC, Health Service, Reduce, Non-Value Added Activity

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 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. 

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.

scholarly journals PENDEKATAN METODE LEAN SIX SIGMA PADA GENTENG PALENTONG

2019 ◽  
Vol 6 (2) ◽  
pp. 111-116
Author(s):  
Julian Robecca ◽  
Gio Patria Mulia
Keyword(s):  
Six Sigma ◽  
Lean Six Sigma ◽  
Value Stream Mapping ◽  
Value Stream

Kriteria penting yang menjadi faktor keberhasilan dalam suatu bisnis dan pertimbangan pelanggan dalam memilih produk adalah mutu produk itu sendiri. Metode Lean Six Sigma merupakan metode pendekatan untuk mengidentifikasi dan menghilangkan pemborosan (waste) atau  aktivitas –aktivitas yang tidak bernilai tambah untuk mencapai kinerja enam sigma. Lean merupakan metode pendekatan yang berfokus pada pemborosan. Six sigma berfokus pada peningkatan kualitas melalui siklus DMAIC yaitu Define, measure, analyze, improve dan control.Objek penelitian adalah genteng palentong, penelitian dilakukan di PG. Mulia Jatiwangi. Permasalahan yang terjadi pada perusahaan yaitu jumlah produksi tidak sesuai dengan yang diinginkan. Metode lean six sigma dibagi menjadi 4 tahapan yaitu define, measure, analyze dan improve. Pada tahap define menggunakan CTQ untuk mengindentifikasi faktor yang mempengaruhi kepuasan pelanggan terhadap genteng dan diagram histogram untuk menentukan cacat paling dominan genteng, tahapan measure dilakukan penentuan cacat genteng, perhitungan level six sigma untuk mengukur kegalan dalam produksi genteng, dan pembuatan value stream mapping untuk mengetahui aliran informasi dan fisik dalam pembuatan genteng. Pada tahap analyze mencari akar penyebab terjadinya cacat dan pemborosan pada genteng dengan menggunakan fishbone, tabel identifikasi waste dan sub waste genteng, dan. Pada tahapan improve dilakukan perbaikan untuk masalah yang sudah dijabarkan dengan analisis 5 why untuk memberikan solusi dalam melakukan perbaikan genteng dengan menggunakan 5W+1H. Hasil dari penelitian diketahui bahwa pada produk genteng palentong mempunyai lima jenis cacat yaitu gopel, pecah, keropos,retak, dan gosong. Jenis cacat yang sering terjadi pada periode 2016 yaitu jenis cacat gopel. Faktor penyebab terjadinya kecacatan yaitu manusia dan metode yang mengakibatkan waste transportation dan waste motion pada proses produksi. Usulan diberikan peneliti untuk meminimalisir cacat pada produk dan meminimasi pemborosan dengan meningkatkan kesadaran dari operator untuk melakukan pekerjaan, memberikan pelatihan, dan membuat standar operasional prosedur dalam melakukan pekerjaan.

scholarly journals APLIKASI LEAN SIX-SIGMA UNTUK MENGURANGI PEMBOROSAN DI BAGIAN PACKAGING SEMEN

2020 ◽  
Vol 7 (2) ◽  
pp. 143
Author(s):  
Reni Dwi Astuti ◽  
Lathifurahman Lathifurahman
Keyword(s):  
Failure Mode ◽  
Six Sigma ◽  
Lean Manufacturing ◽  
Fish Bone ◽  
Lean Six Sigma ◽  
Value Stream Mapping ◽  
Effect Analysis ◽  
Value Stream ◽  
Transportation Motion

Hasil observasi di PT. Holcim Indonesia Tbk, pabrik Cilacap, didapati banyaknya pemborosan di bagian pengepakan semen, termasuk banyaknya produk cacat kemasan, sehingga banyak semen tercecer dan harus mengulangi proses pengepakan. Penelitian ini dilakukan untuk mengidentifikasi pemborosan selama proses pengepakan menggunakan  pendekatan lean manufacturing dengan value stream mapping. Sementara tingkat kualitas dianalisis dengan metode six-sigma. Penyebab kecacatan produk dianalisis dengan fish-bone diagram. Failure Mode and Effect Analysis (FMEA) digunakan untuk merancang ususlan perbaikan. Pemborosan yang teridentifikasi meliputi : transportation, motion, waiting, over processing, dan defect. Usulan perbaikan untuk mengurangi pemborosan yaitu dengan penggabungan stasiun penimbangan dan stasiun pemeriksaan, sehingga memberikan estimasi peningkatan  process cycle effisiensi  dari 39,1% menjadi 46,69. Sedangkan upaya untuk mengurangi cacat produk dilakukan dengan perawatan preventif mesin packer.

scholarly journals ANALISIS PENGENDALIAN KUALITAS DENGAN MENGGUNAKAN METODE LEAN SIX SIGMA DI PT. XYZ

2021 ◽  
Vol 16 (2) ◽  
pp. 13-24
Author(s):  
Ahmad Fauzi ◽  
Moch Tutuk Safirin
Keyword(s):  
Six Sigma ◽  
Value Added ◽  
Lean Six Sigma ◽  
Value Stream ◽  
Sigma Level ◽  
Big Picture ◽  
Production Output ◽  
Fmea Method ◽  
One Machine

XYZ is a company that produces Medical Devices. One of the products produced is 16x16 hydrophilic sterile gauze. One of the factors that affect the quality of a product is the presence of defects in the product and waste which results in a longer lead time for a product. The investigative stages used in this study are using tools: seven tools, Big Picture Mapping, Value Stream Analysis (VALSAT) and then analyzing the causes of defects using the Ishikawa diagram (fishbone chart) where the output of this study is a proposed improvement using the FMEA method ( Failure Mode Effect and Analysis) to eliminate defects and waste that occur. Based on the research results, it is known that the type of waste identified by the calculation of Value Stream Activity and obtained Value Added with a percentage of 84.4%, Non Value Added by 1.0% and Necessary Non Value Added by 14.5%. From the results of production output in December 2019 to November 2020 amounting to 2,650,200 boxes, the number of defects is 1,316 boxes with an average sigma level of 5.16, while in FMEA it is known that the largest defects are spots with an RPN value of 504 and a suggestion for improvement is to place Experienced operators who have gone through the recruitment and training stages on superior qualifications on one machine according to their skills who understand SOPs and operators are given good comfort in the production process.                                                                                                   Keywords: Lean Six Sigma, Seven Waste, DMAIC, FMEA, kasa steril hidrofil 16x16.

scholarly journals Six Sigma as a method of improving the quality of service process

2018 ◽  
Vol 19 (19) ◽  
pp. 10-15 ◽  
Author(s):  
Kamila Kowalik
Keyword(s):  
Six Sigma ◽  
Service Process ◽  
Value Stream Mapping ◽  
Pareto Chart ◽  
Value Stream ◽  
Sigma Level ◽  
Fishbone Diagram ◽  
Mapping Process ◽  
The Impact

Abstract The objective of the analysis conducted and described in this paper has been to present the practical application of the Six Sigma method based on the DMAIC cycle in improving the quality of the service process. The first part of the article contains the theoretical framework of six sigma and the issue of using its tools in the aspect of services. Afterwards, there has been calculated the initial sigma value which indicated the need for improvement. Measurement phase has been developed by the value stream mapping, process FMEA and customer survey which results have been analyzed in Pareto chart and fishbone diagram. Improve phase includes the Impact&Effort Matrix and target sigma level that can be achieved as a result of failures reducing and service quality improvement.

scholarly journals VALUE STREAM MAPPING OF OCEAN IMPORT CONTAINERS: A PROCESS CYCLE EFFICIENCY PERSPECTIVE

2021 ◽  
Vol 8 (4) ◽  
pp. 393-405
Author(s):  
Mohan Saini ◽  
Anastasia Efimova ◽  
Felicita Chromjaková
Keyword(s):  
Six Sigma ◽  
Lean Six Sigma ◽  
Value Stream Mapping ◽  
Container Transportation ◽  
Expert Review ◽  
Value Stream ◽  
Import Containers ◽  
Process Perspective ◽  
Import Container ◽  
Cycle Efficiency

International cargo transportation is majorly dependent on marine transport, which moves 80% of the international cargo. With the increase in vessel size and the same yard area available for container transportation, it is important to study the processes and understand the efficiency of the container operations process. This research paper aims to review the import container transportation process and understand the process cycle efficiency through lean six sigma concepts. The process is evaluated from the operations process perspective and documentation process at one of the ports of India. The research has been designed by conducting an industry expert review on the process of container transportation from vessel berthing to gate out for import containers, utilising lean six sigma principles such as value stream mapping (VSM) and process cycle efficiency. The results have contributed to the existing knowledge in identifying the waste in the container handling process and demonstrated the inefficiency in the system from the perspective of waiting time of containers due to customs examination, scanning, and inter-terminal handling and movement. The process cycle efficiency of 40% is calculated by analysing the detailed time of handling containers from vessel berthing to gate out. A new future value stream mapping is proposed considering the process cycle efficiency. Future studies will focus on studying this process for export containers and benchmarking the results with the top-performing ocean ports globally.

scholarly journals Pemberdayaan dan Penguatan Daya Saing Usaha dengan Penerapan Lean Six-Sigma Concept, Studi Kasus

2018 ◽  
Vol 20 (1) ◽  
Author(s):  
Hari Supriyanto
Keyword(s):  
Quality Control ◽  
Six Sigma ◽  
Net Present Value ◽  
Value Added ◽  
Lean Six Sigma ◽  
Risk Priority Number ◽  
Present Value ◽  
Packaging Process ◽  
Value Stream ◽  
Root Cause

Dinamika dan perkembangan ekonomi global dapat memberikan sinyal positif terhadap pentingnya peningkatan pemberdayaan dan daya saing produk di pasar. Dibutuhkan pemikiran untuk membangun keunggulan kompetitif, yang menjadi dasar bagi peningkatan produksi dan daya saing bisnis. Peningkatan produksi merupakan serangkaian aktifitas untuk membentuk produktifitas. Bila salah satu aktifitas produksi mengalami kegagalam maka akan berpengaruh pada kualitas dan kapasitas produksi. Kegagalan biasanya terindikasi dari waste/ pemborosan yang muncul di sepanjang value stream. Terdapat indikasi defect yang tinggi melebihi 10% di sortir dan packaging process. Permasalahan utama adalah adanya waste/ pemborosan yang mengakibatkan penurunan kualitas dan kapasitas produksi. Paper ini akan mengidentifikasi waste yang terjadi di proses produksi, mencari akar penyebab terjadinya waste, dan membangun alternatif solusi perbaikan.  Diperlukan pemikiran kreatif untuk dapat menaikkan efisiensi sumber daya dan daya saing bisnis di pasar. Metoda yang dipakai untuk menyelesaikan permasalahan adalah Lean six-sigma. Konsep ini menelusuri permasalahan inefisiensi dengan mencari non value added activity dari munculnya waste di sepanjang value stream.  Kemunculan waste selanjutnya diidentifikasi lebih dalam dengan root cause analisys (RCA) dan failure mode and effects analysis (FMEA). Hasil akhir dari FMEA adalah risk priority number (RPN) yang menggambarkan prioritas atas mode resiko untuk dilakukan perbaikan. Dari hasil prioritas dirancang 3 alternatif perbaikan yaitu pelatihan operator, pembuatan SOP proses produksi, dan pelatihan karyawan quality control.   Dengan pendekatan net present value (NPV), maka diperoleh nilai NPV yang positif, artinya alternatif tersebut adalah layak untuk dijalankan. Alternatif ini meningkatkan nilai sigma dari sigma awal sebesar 2,80 menjadi 3,30. Kenaikan nilai sigma akan memberi indikasi adanya penurunan tingkat defect per million opportunities (DPMO), dan berakibat pada penurunan biaya sampai 20%.

scholarly journals Identifikasi Waste pada Waktu Tunggu Pasien Rumah Sakit Nasional Diponegoro dengan Pendekatan Lean Hospital

2017 ◽  
Vol 5 (2) ◽  
pp. 94-103
Author(s):  
Jessica Christanti Pualamsyah ◽  
Sudiro Sudiro
Keyword(s):  
Internal Medicine ◽  
Waiting Time ◽  
Medical Records ◽  
Value Added ◽  
Wait Time ◽  
Mean Value ◽  
Value Stream Mapping ◽  
Time Duration ◽  
Value Stream ◽  
Outpatient Unit

Outpatient waiting time based on minimum standart of care is defined as a time duration since patient in registrated until they meet the doctor. Lean management is a method that could improve outpatient process. There was persistence complain in outpatient waiting time in Diponegoro National Hospital since May 2016 until November 2016. Therefore, lean is expected to improve outpatient wait time. Based on Lean theory, waste is comprised of waste defect, overproduction, transportation, waiting, inventory, motion, overprocessing, and non-utilized talent. This study is going to identified waste that occurred in internal medicine outpatient.  　　　This was qualitative study research and conducted by observation, indepth interview, and focussed group disscusion. Total of key informant was 10 internal medicine patients and 6  hospital staffs, including  registration, administration, information technology (IT) , procurement, helper, and  nurse. Total of informant triangulation was 2 informants, including head of outpatient unit and medical records unit. Waste identification was done by value stream mapping analysis and value-added assessment. Root cause analysis (RCA) which used in this study was 5 whys method.  　　　The longest activity in outpatient  was waiting in registration booth with mean value of 30,9 minutes, the second was waiting for doctor activity with mean value of 25,2 minutes and the third was waiting medical records to be given by helper with mean value of 8,8 minutes. Waste waiting, overprocessing,  defect,  inventory, motion  were  found in this study. It recommends an establisment of flowchart for patient, interdepartment coordination, and Standar Operation Procedure (SOP). Procrument for medical record facility and implementation of 6 S culture are mandatory.

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