Implementation of Lean Six Sigma for production process optimization in a paper production company

Adeodu, Adefemi; Kanakana-Katumba, Mukondeleli Grace; Maladzhi, Rendani

doi:10.3926/jiem.3479

Cited by 23 publications

(27 citation statements)

References 26 publications

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“…There was room for improvement in the firm because of its waste generation and inadequate operational efficiency. The choice of the case study methodology stemmed from the fact that it is flexible and allows both qualitative and quantitative analyses [34]. It is also more sensitive to organisations' plights and offers a suitable way to investigate the root causes of certain difficulties that organisations encounter [41,[46][47][48][49][50].…”

Section: Methodsmentioning

confidence: 99%

“…Adeodu, Kanakana-Katumba and Maladzhi [34] used the LSS method for production process optimisation in a paper production firm in Nigeria. The study provided a practical guided approach for LSS implementation in solving the organisation's challenges relating to productivity and manufacturing.…”

Section: Literature Reviewmentioning

confidence: 99%

“…VSM is a Lean tool that is suitable for the design and analysis information flow to enhance effective delivery to customers [54]. Furthermore, its application to reducing waste in an organisation's processes has been reported [34]. This is to provide insight into the areas where improvements are necessary.…”

Section: Problem Definition Phase (Define)mentioning

confidence: 99%

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Application of Lean Six Sigma to a Small Enterprise in the Gauteng Province: A Case Study

Magodi

Daniyan

Mpofu

2022

SAJE

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The quest to improve customer satisfaction is one of the core aims of businesses in the competitive global market. This paper aims to apply the principles of Lean Six Sigma for continuous improvement in a small enterprise in the service industry in South Africa. A case study approach was used to carry out the investigation using the Lean Six Sigma ‘define measure analyze improve and control’ (DMAIC) approach. Data collection was done in a face-to-face interview and brainstorming session with the business owner and consultants. Observations and a time study were also used to collect additional data. The results showed a lack of knowledge and awareness of Lean Six Sigma among the business owner and the consultants. The commitment to and engagement of management in the project contributed positively to the implementation of the DMAIC approach. The process improvement changes were applied over a period of three months, after which the process performance was reviewed. The case study resulted in a 60.3% reduction in total non-value-added time and an increase in both the value-added time (53.85%) and the amount of uptime (10.74%). Furthermore, downtime was also reduced (47.7%). This study shows that the application of the Lean Six Sigma tool could solve the challenges of productivity and waste in a bookkeeping and tax consulting SME in the Gauteng province with a direct implication for operational efficiency and customers’ satisfaction.

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Section: Methodsmentioning

confidence: 99%

Section: Literature Reviewmentioning

confidence: 99%

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Application of Lean Six Sigma to a Small Enterprise in the Gauteng Province: A Case Study

Magodi

Daniyan

Mpofu

2022

SAJE

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“…This results in easily identifying waste and unsafe practices in the complex process. Material handling and safety are critical aspects in production free flow and advance the value chain at an optimal cycle time [30]. The constraint of material is a result of unlevelled production schedules causes too many changeovers in material handling.…”

Section: Materials Handling Support To Improve Productivitymentioning

confidence: 99%

Productivity Improvement using Simulated Value Stream Mapping: A Case Study of the Truck Manufacturing Industry

Poswa¹,

Mpofu²,

Adenuga³

2022

Preprint

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The accumulation of process waste in the production line causes fluctuations, bottlenecks, and increased inventory in workstations disrupting process flow. In this paper, the aim is the use a simulated value stream mapping (SVSM) as a lean assessment tool for decision-making in the continuous improvement process to influence and provide consideration and consistency on productivity improvement in the production system. The proposed methodology applied discrete event simulation for production process operations improvement to eliminate non-value adding times and provides good quality products at the lowest cost and highest efficiency. The results are the analysis of the current state of the production system in a South African truck manufacturing industry small and medium enterprise (SMEs) as a potential solution for the production system future state. The identified non-value adding times in the 6 most critical workstations was eliminated by SVSM which resulted in a productivity improvement of 4%, most importantly bringing the productivity to 95% and total cycle time improvement to 451 for small units and 466 for large units. The results proposed combined VSM and Simulation techniques which enhance the LEAN application by DES to increase productivity and performance improvement to remain competitive in the global economy.

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“…The main focus of six-sigma is on process control, continuous improvement, customer needs, statistical analysis and business growth [2][3][4][5][6]. Most widely used approach of the six sigma is DMAIC cycle i-e Define, Measure, Analyse, Improve and Control is a five-step six-sigma improvement model adopted by manufacturing and service organisations to improve their current capacities of existing processes [7][8][9][10][11][12]. There are variety of the supporting tools which can be used at various phases of the six sigma methodology.…”

Section: Introductionmentioning

confidence: 99%

Practical application of six SIGMA methodology to reduce defects in a Pakistani manufacturing company

Wassan¹,

Hulio²,

Gopang³

et al. 2022

J Appl Eng Science

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All over the world six sigma is being adopted as a quality improvement approach towards zero defects. Unfortunately, the adoption of the six sigma methodology in manufacturing companies is very rare in developing countries due to different challenges and Pakistan is standing in the same row. This article demonstrates the practical use of various six sigma tools throughout Define, Measure, Analyze, Improve and Control (DMAIC) cycle by conducting a case study of manufacturing company in Pakistan. The potential problem was the external leakage defect in refrigerator during its production. The goal of this project was to identify critical root causes of external leakage and eliminate them with the help of six sigma DMAIC methodology. Project charter, Pie chart, Bar chart of faults, Suppliers Input Process Output (SIPOC), Voice of Customer (VOC) and flow process map were used to define the problem, its scope and process routing. Pareto chart was used to identify sub defects and sigma level was calculated for the existing process. Feed rate, capillary action of filler material, cleanliness, visual inspection and unsuitable heat input were the major causes of external leakage, identified by cause and effect diagram. Cause and effect matrix was developed to rank the identified causes. Further, DoE was performed to improve the process by conducting different alterations in the parameters. In order to control the process, FMEA sheet was prepared to sustain the process improvements. The FMEA control plan needed to be revised at specific time intervals to attain continuous process improvement. External leakage defect was reduced by 30% and service call rate (SCR) was improved with lower complaints from customers.

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Implementation of Lean Six Sigma for production process optimization in a paper production company

Cited by 23 publications

References 26 publications

Application of Lean Six Sigma to a Small Enterprise in the Gauteng Province: A Case Study

Application of Lean Six Sigma to a Small Enterprise in the Gauteng Province: A Case Study

Productivity Improvement using Simulated Value Stream Mapping: A Case Study of the Truck Manufacturing Industry

Practical application of six SIGMA methodology to reduce defects in a Pakistani manufacturing company

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