Implementation of six sigma in a manufacturing process. Case study sheet extrusion process benefits of doing kaizen following a 6s process. Pdf this article discusses the successful implementation of six sigma methodology in a high precision and critical process in the manufacture of. Value stream management for lean officea case study. The objectives of this study is to propose an improvement on the process time that would result in either reduction of workstation idle time, minimize the number of. A flexible process improvement case study with data sets and tools for instructors to deliver multiple learning objectives. Production and oee improvement for an 800 tons stamping press master thesis work 30 credits, dlevel product and process development, concurrent engineering master thesis programme innovation and product design author aurelien narses school of innovation, design and engineering, malardalen university, box 325, se631 05 eskilstuna. In part one, the case study elminates a significant cost for the company delivery delays.
This makes it difficult to assess the problem due to lack of definition of office workers idle time. Two packing lines were suffering from lost output, high rework and high waste at its assembly stations. Data from a study carried out on a sample of manufacturing industry small scale solar appliances shows that motion and time study implementation and assembly line balancing contributes positively towards achieving productivity. The hawkins supply company is currently faced with an inventory rotation problem. Value stream mapping is used to visualize the current processes for easier understanding and problem identification. This case study looks at how silfex has streamlined its manufacturing processes. Kaizen improvement event k188 in an automotive industry. As lean developed since its origins in the automobile industry, it has been extended to apply to various. Firstly a detailed analysis of the process of a specific produced piece named x is performed.
Arena software was employed to select the suitable option. Framework for continuous improvement of production processes. Mohanram department of mechanical engineering, psg college of technology, coimbatore, 641 004, india s. Our ability to supply a system that directly addresses the needs of a material process starting with benchscale testing and ongoing process optimization enables us to help.
A medical device manufacturer was using polyisobutylene polymer to produce electrocardiogram heart patches. Pdca cycle as a part of continuous improvement in the. A case study of inventory management in a manufacturing. Oct 01, 2004 process mapping and kaizen blitz activities were utilized during analysis of key business processes within this company. A lean manufacturing process case study rahani ar, muhammad alashraf faculty of mechanical engineering.
Process improvement by eliminating a hazardous, manual labor task feb 11, 2015 no comments case studies. As lean six sigma projects rapid improvement with structure and discipline peter l. Such was the case in the productivity improvement project. The study demonstrates measurable results realized through use of process mapping tools, kaizen blitz activities, formalized and documented work instructions and work measurement tools. In this paper a case study of a small process industry, some changes in the. The plant comes under energy distribution group which mainly produces switchgear, switch board, motor and transformer. Kaizen improvement event k188 in an automotive industry a. The supplying of mf is done through seven deposits six with automatic activation and one manual, which supply the cork stoppers to the first type of machines in. Process improvement pm governance combined with agile tools improves delivery and quality of financial services programs changing state and federal regulatory compliance challenges caused this company to reinvent its. Tollgate adventure a 24 hour dmaic tollgate simulation designed for lean six sigma team sponsors and champions. This study aims to identify the key factors that influence inventory management practices, investigate efficient and effective inventory management approaches, and examine the impact of supplier cooperation on supply chain improvement.
Collins, muthusamy, and carr 2015 provide us with a case study that. This case study looks at how silfex has streamlined its manufacturing processes while being mindful of industry constraints. The results show that the key tacit elements are mediated by behavioural factors. A combination of case study and action research has been used as the research method. Kaizen improvement event k 188 in an automotive industry a case study mohd anees siddiqui department of mechanical engineering, integral university lucknow, india abstractthis paper is a case study of an automotive industry in which the kaizen improvement activity entitled k188 is performed in the shop floor and the kaizen target are made. Lean manufacturing implementation using value stream. A case study on improving productivity by reducing operation. As a core value the company had a belief in providing customer. Availability sampling is based on the available chance of the subject during the study 11. Business process improvement the benefit one challenging project tmmin had to deal with was the ics inventory and costing system for its coverage and complexity was comparable to smallscale of erp enterprise resource planning system. A simulation is the replication of the operation of a realworld process or system overtime. Silfex was selected for the ame manufacturing excellence award because of its collection and use of data to improve its strategic planning and operations. A case study, in food manufacturing operating system is modeled and analyzed the behavior of system.
Improvement of a manufacturing process the case study of corticeira amorim equipar francisco delgado department of engineering and management, instituto superior tecnico abstract corticeira amorim, company where this study is conducted, is the world leader in this sector and. Initiated in the automotive industry, continuous improvement were implemented to improve the manufacturing process change. Case study of a plastic manufacturing and sales company. The vr for quality case study detailed how one professional harnessed vr to bring. Mexico 2department of industrial and manufacturing engineering institute of engineering and technology. Through a case study in a medium scale faundary, the present work formulate a comprehensive strategy of six sigma in indianfoundary. Quality improvement with statistical process control in. Bepex specializes in manufacturing process improvement. In ppc, we build databased models process characterization is an activity in which we. We work directly with our customers to design process specific industrial equipment for a range of applications. Lodrina masiyazi, kudzanayi chiteka, mncedisi trinity dewa, and donald museka.
Intl conference image processing, computers and industrial engineering icicie2014 jan. In manufacturing, corporate growth and profitability are more challenging than ever before. The vapp approach in this section the vapp approach is introduced. The critical link between process improvements and business results pdf, 382 kb a delivery improvement case study from pune, india, demonstrates how six sigmas focus on the relationships among a projects business y, customer y, process y and inputs xs can achieve breakthrough results. Manufacturing process improvement case studies bepex. In this paper, we focus on inventory management in a manufacturing company in china.
Silfex manufactures silicon components and assemblies used in the solar, optics, and semiconductor equipment industries. After this has been achieved the focus will be altered to improving the process while observing it. Production flow analysis through value stream mapping. Process improvement in pharmaceutical industry through kaizen. A case study of defects reduction in a rubber gloves. Process improvement in pharmaceutical industry through. Lean manufacturing, value stream mapping, cycle time, takt time. The operators and maintenance team had tried to resolve the problem for 2 years with little success and had resorted to slowing the line down. This research provides a case study performed on a rope manufacturing process. Pdf application of sixsigma for process improvement in. A socks manufacturing company in india turned to tqm to improve its supply chain. This difficulty stems from the fact that some supplies must be used prior to a stated expiration date. Case study this case study is conducted at siemens ltd. The paper presents a case study of the practical use of deming cycle in a manufacturing company, from the plastics processing industry, from the sector of small and mediumsized enterprises.
A lean manufacturing process case study rahani ar, muhammad alashraf faculty of mechanical engineering universiti teknologi mara,40450. Modifying production line for productivity improvement. Process vs assembly parts manufacturing and assembly automobiles cell phones computers. The paper is a study of literature in the field of continuous improvement and characterized by a cycle of. They solved this problem by applying lean six sigma techniques, such as a datadriven problemsolving process, to devise solutions to waste issues. Productivity improvement through process optimization. Manufacturing process improvement bepex case studies. First, this study will briefly summarize the five phases of the six sigma methodology. Improving business processes for increased operational. Work standardization this study consists of conducting time study of sewing operations. Procedia engineering 41 2012 1727 a 1734 18777058 2012 published by elsevier ltd. Lean six sigma and process improvement case studies. A case study of continuous improvement as a dynamic. While this approach was innovative when bratton applied it a quartercentury.
In this study availability sampling techniques was used. In this industry the process flow layout of garment manufacturing which have interdependency. Latest manufacturing process improvement techniques. A sample of selected process improvement projects executed during the study is described next to show the approach to problem analysis, solution, and implementation. Lean manufacturing implementation using value stream mapping. The objectives of this study is to propose an improvement on the process time that would result in either reduction of workstation idle time, minimize the number of workstation, and facilitate the. A case study on improving productivity by reducing.
Later, how the vapp approach was applied at the swedish manufacturing company is described. Also, a proposed solution may emerge early in the measure and analysis phase, leading to an emphasis on planning and implementation in the improve phase. Manufacturing improvement case studies lauras international. In this regard, validation evidence for two premises is sought through a case study at a small furniture production company. Standridge manufacturing and quantitative analysis performed using tools such as mathematical optimization and discrete event simulation. Next, it will briefly describes the application of six sigma in various functional areas other than manufacturing operations. Rajenthirakumar department of mechanical engineering, psg college of technology, coimbatore, 641 004, india email adres. Improving productivity by reducing operation cost as six sigma process improvement 151 sequentially. A case study of continuous improvement as a dynamic capability. This case study is conducted at switch board plant. More technically comprehensive descriptions of these innovations are documented separately in the case study based on the company 3.
Hopefully this approach will induce controversy, an essential element of the educational process. A welldefined problem statement will ensure a successful outcome of a project improvement process. Improvement of a manufacturing process the case study of. Finally the results of the case study are discussed and conclusions are drawn. Thus, the simulation method is the best method to identify problems or bottlenecks in the. Performance anagement and lean process improvement results washington 4 public dashboard. Continuous improvement beyond manufacturing murray states. This study examines six sigma, lean, and continuous improvement systems in.
Six sigma is a quality improvement approach that aims to reduce the number of. A case study of lean, sustainable manufacturing 12 g. Part two of the case study looks at the broadening of the application of process improvement beyond deliveries. A case study of defects reduction in a rubber gloves manufacturing process by applying six sigma principles and dmaic problem solving methodology. Introduction to production process characterization 3. This study has significantly increase the efficiency of foundry industry and reduce scrap and waste in sand casting process which improve the production efficiency.
A case study jaskaran s ingh 1 and g urinder s ingh b rar 2 1 mechanical engineering department, guru nanak dev engineering college, ludhiana141006, india. In addition, primary and secondary source of data has been used. Process improvement in precision component manufacturing. Although the customers material usage was relatively low, the feed material was only available in 79 lb bale form. Value stream management for lean office a case study.
Productivity improvement through lean manufacturing tools. Examples from healthcare, government, manufacturing, education, and. Initially the research will start off with a case study to build a thorough understanding of the business and processes. Fur thermore, the defect rate can be measured by calculating. This paper reports learning and application of a few significant techniques to improve basic business practices in a company, which. Jun 06, 2014 silfex manufactures silicon components and assemblies used in the solar, optics, and semiconductor equipment industries. It is followed by the presentation of the study method adopted in the case study. The bottleneck of the process was selected to study and improve in order to increase manufacturing capacity. Rajenthirakumar department of mechanical engineering. This is an era of quality management and quality is a parameter for the selection of a product or service because the customer wants a defects free product or service. Markarian 8 suggests that not only can the process improvement generated by six sigma be used in manufacturing operations, as it is the case for the project presented in this paper, but it can also be expanded to improve business sectors. Taking process improvement beyond the quality department pdf, 326 kb. Performance anagement and lean process improvement results washington 8 counterproductive behaviors with effective, goaloriented activity.