Lean six sigma for manufacturing industry: a review

Siregar, Khawarita; Farida, Ariani; Ginting, Erwin; Dinda, M. P. Trie

doi:10.1088/1757-899x/505/1/012056

Cited by 7 publications

(7 citation statements)

References 41 publications

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“…To have a broader knowledge on applying six sigma DMAIC approach in manufacturing industries, the reader is encouraged to refer to Siregar et al (2019), Tarimarjok et al (2020, Setiawan and Debora (2020), Dominic et al (2021) and Tampubolon and Purda (2021) who conducted a state-of-art literature review on applying LSS in the manufacturing and service industries. More specifically, the review aims at highlighting the objectives and benefits of using LSS in manufacturing industries, its tools as well as identifying the main success and failure factors of implementing LSS in those industries.…”

Section: Previous Studiesmentioning

confidence: 99%

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A case study on implementing Lean Six Sigma: DMAIC methodology in aluminum profiles extrusion process

Araman¹,

Saleh

2022

TQM

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PurposeThis paper aims to investigate the sources of variation in aluminum profiles hot extrusion process for the purpose of process capability improvement at National Aluminum and Profiles Company (NAPCO) in Palestine. The critical-to-quality characteristics (CTQ) have been determined as base variables to measure the process capability.Design/methodology/approachThe DMAIC (Define, Measure, Analyze, Improve, and Control) Lean Six Sigma (LSS) approach has been adopted to conduct this study. More specifically, historical data analysis and PARETO charts have been employed. The defects' root causes have been determined using the cause-and-effect diagram and decision matrix. A course of suggested actions has been established to help in improving extrusion process capability. Minitab-18 software was used for conducting inferential statistical analysis. A case study considering a geometry CTQ of D3 dimension of bottom sash aluminum profiles 4,332 was selected for analysis.FindingsThe results indicated a reduction in DPMO from 89,649 to 15,659, sigma level was improved from 2.84 to 3.65, process yield was improved from 91.04% to 98.43% and cost was reduced from U$75,972 to U$13,250.9 (i.e. a saving of U$62,721). Studying and improving the sigma level of the extrusion process would yield fewer defective products and consequently fewer customer complaints. A validation process which has been conducted during the year 2019 showed a consistent improvement that aligns with the first stage of improvement made on October 1, 2018.Research limitations/implicationsThis study focuses on only one critical quality characteristic (CTQ), namely, a geometry CTQ of D3 dimension of bottom sash aluminum profiles 4,332 produced by NAPCO was selected for analysis.Practical implicationsThis study would be useful for researchers and practitioners to improve the process capability in aluminum profiles manufacturing industries in general and hot extrusion processes in particular.Originality/valueMany previous studies on applying LSS-DMAIC methodology have been conducted in aluminum industries in developed countries. According to the literature, it is highly recommended to have more case studies of applying LSS-DMAIC in different industries in developing countries. NAPCO is the only aluminum manufacturing plant in Palestine that hotly extrudes and coats aluminum profiles. Hence, the present study is the first of its kind in NAPCO and in Palestine. Projecting the assessment of the impact of process improvement opportunities and capability analyses into monetary measures are also innovative.

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Section: Previous Studiesmentioning

confidence: 99%

“…To have a broader knowledge on applying six sigma DMAIC approach in manufacturing industries, the reader is encouraged to refer to Siregar et al. (2019), Tarimarjok et al.…”

Section: Literature Reviewmentioning

confidence: 99%

A case study on implementing Lean Six Sigma: DMAIC methodology in aluminum profiles extrusion process

Araman¹,

Saleh

2022

TQM

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“…To ensure smooth implementation Top management commitment is a must in all cases. 17 (Siregar et al, 2019) The focus on several journals published on a particular topic is subject to review Indonesia Almost all types of manufacturing industries such as shipping, automotive, paper, pharmaceuticals, iron, etc. 21 journals reviewed, there are 19 journals for case study of the application of LSS.…”

Section: Indiamentioning

confidence: 99%

Lean six sigma implementation, a systematic literature review

Tampubolon

Purba

2021

Int. J. Prod. Manag. Eng.

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<p class="TtuloAbstract">Organizations must be able to meet customer needs in today’s complex market situation and business environment, the needs and essentials for their satisfaction such as high product quality, competitive costs and faster delivery. Organization need to apply a comprehensive concept and method on managing this requirement. This systematic review intends to identify how Lean Six sigma implementation in many industries. Lean Six Sigma (LSS) is a method that has been widely used in research in various fields and continues to grow, to get the most common solution it is necessary to review the method. This research is to observe concept and method still relevant to be use and effectively improved the business performance and customer satisfaction. For the identity of the LSS Papers, a total of 50 research papers were reviewed which met the criteria, Research object, country of research and year of publication and Result of research. The result show that LSS is still being used and successfuly help the organization to improve their competitiveness, improve quality, reduce costs, increase customer satisfaction, increase productivity, and increase employee morale.</p>

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“…They understand well the causes and consequences of choices in terms of impact on the system, the products, the employees, and more, in order to do their best to succeed. (Bendell, 2006;Gupta and Jain, 2013;Nithia et al, 2015;Pacheco et al, 2015;Costa et al, 2018;Ismail et al, 2019) SS (Bendell, 2006;Oke, 2007;Kumar and Antony, 2008;Gamal Aboelmaged, 2010;Pacheco et al, 2015;Costa et al, 2018;Patel and Desai, 2018) L6S (Alsmadi and Khan, 2010;Antony et al, 2017;Alexander et al, 2019;Siregar et al, 2019) TOC (Kasemset, 2011) 2 BFT Lead-time reduction LM (Gupta and Jain, 2013;Bhamu and Singh Sangwan, 2014;Pinho and Mendes, 2017;Costa et al, 2018;Gladysz and Buczacki, 2018) SS (Oke, 2007;Kumar and Antony, 2008;Costa et al, 2018;Patel and Desai, 2018) L6S (Alsmadi and Khan, 2010;Antony et al, 2017;Alexander et al, 2019) TOC (Rahman, 1998;Ikeziri et al, 2019) TQM (Nandurkar et al, 2014) 3 BFT Quality improvement LM (Gupta and Jain, 2013;Bhamu and Singh Sangwan, 2014;Yusup et al, 2015;Pinho and Mendes, 2017;Costa et al, 2018;Ismail et al, 2019) SS (Oke, 2007;Gamal Aboelmaged, 2010;…”

Section: • Trained Actors On the Philosophies Of Quality Improvementmentioning

confidence: 99%

“…Therefore, one must be able to identify the full list of improvements and determine the right timing for each one to be done. (Arnheiter and Maleyeff, 2005;Gupta and Jain, 2013;Bhamu and Singh Sangwan, 2014;Sundar et al, 2014;Nithia et al, 2015;Yusup et al, 2015;Pinho and Mendes, 2017;Costa et al, 2018) SS (Arnheiter and Maleyeff, 2005;Oke, 2007;Kumar and Antony, 2008;Van Iwaarden et al, 2008;Tjahjono et al, 2010;Costa et al, 2018) L6S (Albliwi et al, 2015;Antony et al, 2017;Muraliraj et al, 2018;Ruben et al, 2018;Alexander et al, 2019;Siregar et al, 2019) TQM (Al-Khalili and Subari, 2014;Dedy et al, 2016) 2 CFF Lack of top management commitment LM (Gupta and Jain, 2013;Bhamu and Singh Sangwan, 2014;Alhuraish et al, 2015;Nithia et al, 2015) SS (Kumar and Antony, 2008;Van Iwaarden et al, 2008;Tjahjono et al, 2010;Alhuraish et al, 2015) L6S (Alsmadi and Khan, 2010;Albliwi et al, 2015;Muraliraj et al, 2018;Ruben et al, 2018;Alexander et al, 2019;Siregar et al, 2019) TQM (Al-Khalili and Subari, 2014;Dedy et al, 2016) 3 CFF Resistance to change LM (Gupta and Jain, 2013;Alhuraish et al, 2015;…”

Section: • Trained Actors On the Philosophies Of Quality Improvementmentioning

confidence: 99%

Product Quality Improvement Policies in Industry 4.0: Characteristics, Enabling Factors, Barriers, and Evolution Toward Zero Defect Manufacturing

Psarommatis

Prouvost

May

et al. 2020

Front. Comput. Sci.

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In the competitive market of manufacturing, quality is a criterion of primary importance in order to win market share. Quality improvement must be coupled with performance point of view. Lean Manufacturing, Six Sigma, Lean Six Sigma, Total Quality Management, Theory of Constraints, and their combination are philosophies dedicated to this goal. This study is a literature review on the implementation of these philosophies to improve quality of processes and products in a system, and also covers the commonalities and differences with Zero Defect Manufacturing (ZDM) philosophy. In this study, 45 articles have been analyzed. These articles have been selected by a research on several scientific libraries with specific keywords. The methodology is based on a list of information extracted from each paper. The data searched are on the tool selections, critical factors of implementations and the benefits obtained from them. Based on the review and analysis of the literature and practices, we provide the top 10 main components of the tools used for quality improvement, enabling factors, benefits, and barriers to implementation. Moreover, we present and discuss categorization of quality improvement methods and the way toward ZDM. The need of standardized toolkits for different levels of maturity in quality management systems and a better education have been enlightened. Thanks to technological improvement in information flow management, ZDM seems close to be achieved even though some new risks and wastes have to be taken care of within the implementation.

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Lean six sigma for manufacturing industry: a review

Cited by 7 publications

References 41 publications

A case study on implementing Lean Six Sigma: DMAIC methodology in aluminum profiles extrusion process

A case study on implementing Lean Six Sigma: DMAIC methodology in aluminum profiles extrusion process

Lean six sigma implementation, a systematic literature review

Product Quality Improvement Policies in Industry 4.0: Characteristics, Enabling Factors, Barriers, and Evolution Toward Zero Defect Manufacturing

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