Leveraging Lean Six Sigma: Reducing defects and rejections in filter manufacturing industry

Guleria, Prateek; Pathania, Abhilash; Bhatti, Himani; Rojhe, Kuldeep Chand; Mahto, D. G.

doi:10.1016/j.matpr.2021.03.535

Cited by 11 publications

(4 citation statements)

References 17 publications

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“…There are many cases where the improvement rate is much more significant, but it seems that these cases are not as often. These findings are based on the research of other authors such as [57][58][59][60][61][62][63][64][65][66][67][68]. Based on a comparison of the classical indicators, the change achieved in the process is slightly above average.…”

Section: Discussionmentioning

confidence: 90%

Algorithm for Process Innovation by Increasing Ideality

Sojka

Lepšík

2022

Processes

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Continual efforts to have better processes lead us to search for new ways to improve and innovate. One of the most powerful approaches to innovating technical systems is the TRIZ (Theory of Inventive Problem Solving). TRIZ is, unfortunately, very hard to learn and adequately use. This paper introduces a new comprehensive algorithm for the innovation of processes in production based on TRIZ principles. The Algorithm for Process Innovation by Increasing Ideality (AP3I) helps search for innovative ways to improve or change the process—either the whole process or its segments. Besides the original TRIZ, AP3I is easier to use and might be applied by engineers in industrial practice. On the other hand, results from AP3I are probably weaker compared to full TRIZ. Still, the AP3I can be very helpful in efforts to improve processes and can provide powerful ideas. The overall algorithm is also demonstrated in case studies on processes of packing and assembly.

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Section: Discussionmentioning

confidence: 90%

Algorithm for Process Innovation by Increasing Ideality

Sojka

Lepšík

2022

Processes

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“…Lean manufacturing and Six Sigma techniques are used to increase efficiency (Guleria et al, 2021;Luiz et al, 2019;Mitra, 2020;Scheller et al, 2021). Due to efficiency issues or low process productivity cycles in the train carriage assembly process, there has been a significant reduction in waiting time, increased value-added time, and a significant decrease in non-value-added time (Daniyan et al, 2022).…”

Section: Introductionmentioning

confidence: 99%

Reducing Defects Using DMAIC Methodology in an Automotive Industry

Imansuri,

Chayatunnufus,

Safril

et al. 2024

Spek Ind

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Quality is when it meets the wants and expectations of customers or even exceeds them. Every company must raise the quality of its current products and services. A complete and adaptable approach for establishing, maintaining, and maximizing company success is Six Sigma. Define, Measure, Analyze, Improve, and Control (DMAIC) is one of the tools used to implement Six Sigma. PT. KRM is one company engaged in the automotive sector, which produces Colt Diesel trucks. This research focuses on the welding processes. Defective products were found in as much as 5% of total production, exceeding the company's target of 3%. This research was conducted to determine the process capability based on product defects with the Six Sigma DMAIC method approach, then to find out the proposal for implementing quality control by analyzing the causes of defects in the production process and then looking for continuous improvement with the 5W+1H concept. The improvement was made to decrease the DPMO value of 4.496 and increase the sigma value of 0.19. This study demonstrates how the Six Sigma DMAIC approach can improve the quality of the cabin production process for the part side outer pillar LH. This case can help company managers apply Six Sigma methods to solve complex problems in other processes.

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“…Guleria et al [16] implemented Lean Six Sigma in an automobile fuel filter manufacturing company that had a high rejection rate. The company was generating losses and could not supply the demand of its customers in the stipulated time.…”

Section: Introductionmentioning

confidence: 99%

Powder Detergent Packaging Line Improvement by Lean Six Sigma DMAIC Methodology

Pushug,

Ramírez,

Simbaña

et al. 2024

Enfoque UTE

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This investigation was a case of study in the powder detergent packaging line and aimed to reduce all those wastes that do not add value to the product, increasing the cost of production. Reducing or eliminating waste within the manufacturing industry becomes necessary for sustainable businesses over time and keeps generating development. To achieve it, the Lean Six Sigma DMAIC methodology was implemented in a detergent powder packaging line, to identify the problems that afflicted and made production more expensive. By using quality tools (such as Pareto and Ishikawa diagrams, 5S application, Poka-Yokes, SMED, training personnel, and standardizing processes) it was possible to reduce unproductive times. Energy consumption was reduced by up to 20 %, also efficiency and machine availability increased by 10.98 % and 7.32 %, respectively. The general performance of the line increased by 15.16 %, which translates into significant monthly savings of USD 71 442.05. By applying these improvement techniques, the most significant efficiency was registered in 1 kg packages, going from 47 % to 89 %, approximately. To maintain this productivity and even to perfect it, it is necessary to hire specialized personnel who know the production processes and industrial operations.

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Leveraging Lean Six Sigma: Reducing defects and rejections in filter manufacturing industry

Cited by 11 publications

References 17 publications

Algorithm for Process Innovation by Increasing Ideality

Algorithm for Process Innovation by Increasing Ideality

Reducing Defects Using DMAIC Methodology in an Automotive Industry

Powder Detergent Packaging Line Improvement by Lean Six Sigma DMAIC Methodology

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