8/10/2019 Lean Six Sigma-End Sem
1/26
LEAN SIX SIGMAEND-TERM REVIEW
Prepared By:
Deep Dave
Industrial Engineering
11BIE020
Guided By:
Dr. Abhishek Kumar
Dept. of Industrial Eng.
PDPU
8/10/2019 Lean Six Sigma-End Sem
2/26
INTRODUCTION
Todays manufacturing and business environments are reaching a point
that competition for survival and market share is an obligation.
Tracking the global economy will show that being good is not enough,
therefore each organization really strive for excellence if want to stay in
the market.
Every single organization is looking for one single outcome
PROFIT
8/10/2019 Lean Six Sigma-End Sem
3/26
PROFIT is not a single concept but comes with manyimportant implications:
P- Process excellence
R- Resources Management
O- Oriented to a Goal F- Financially Strong
I- Innovativeto stay ahead of competition
T- Timely deployment of strategies
In order to be a leader, most companies are realizingthat traditional management, manufacturingprocesses, and other historic approaches, are notenough.
More effective methods are needed:
Six Sigma
Lean Manufacturing
8/10/2019 Lean Six Sigma-End Sem
4/26
Why Lean Six-Sigma?
8/10/2019 Lean Six Sigma-End Sem
5/26
Lean Management Philosophies
8/10/2019 Lean Six Sigma-End Sem
6/26
Main Disadvantage of Lean
Management In LS Profit can not be calculated in monetary value as opposed to Six
Sigma where with the help of Taguchi loss function we can show the
reduction in loss(or gain of profit) in terms of monetary value.
8/10/2019 Lean Six Sigma-End Sem
7/26
Six Sigma
Six Sigma is one of the most potent strategies ever developed to
accelerate improvements in processes, products, and services, and to
radically reduce manufacturing and/or administrative costs and improve
quality. It achieves this by relentlessly focusing on eliminating waste and
reducing defects and variations.
8/10/2019 Lean Six Sigma-End Sem
8/26
WHAT Is DMAIC?
DMAIC is the most powerful tool of Six-
Sigma for Continuous improvement.
A logical and structured approach to
problem solving and processimprovement.
An iterative process (continuousimprovement)
A quality tool which focus on changein management style.
8/10/2019 Lean Six Sigma-End Sem
9/26
8/10/2019 Lean Six Sigma-End Sem
10/26
Lean Six Sigma
Lean Six Sigmais a methodology that relies on a collaborative
team effort to improve performance by systematically
removing waste; combining lean manufacturing/lean
enterpriseand Six Sigmato eliminate the eight kinds of waste
(muda).
http://en.wikipedia.org/wiki/Lean_manufacturinghttp://en.wikipedia.org/wiki/Lean_enterprisehttp://en.wikipedia.org/wiki/Lean_enterprisehttp://en.wikipedia.org/wiki/Six_Sigmahttp://en.wikipedia.org/wiki/Muda_(Japanese_term)http://en.wikipedia.org/wiki/Muda_(Japanese_term)http://en.wikipedia.org/wiki/Six_Sigmahttp://en.wikipedia.org/wiki/Lean_enterprisehttp://en.wikipedia.org/wiki/Lean_enterprisehttp://en.wikipedia.org/wiki/Lean_manufacturing8/10/2019 Lean Six Sigma-End Sem
11/26
8/10/2019 Lean Six Sigma-End Sem
12/26
Lean Six Sigma- 7 MUDAs
Identify and reduce:
Defects (repair, rework, scrap)
Overproduction (inventory)
Transportation (conveyance)
Waiting (queue time)
Inspection (reliance on mass inspection/
verification)
Motion (parts, paper, people)
Process, itself (over-processing, long cycles)
8/10/2019 Lean Six Sigma-End Sem
13/26
8/10/2019 Lean Six Sigma-End Sem
14/26
A Case Study
AIM- Defects Reduction in a Rubber Gloves Manufacturing Process.
8/10/2019 Lean Six Sigma-End Sem
15/26
1. DEFINE
Voice of the customer (i.e. customer requirements): the problem selected
to be tackled through this project was to reduce/eliminate quality defects
(i.e. holes/stains) on gloves .
In order to ensure that the research is in-control and focuses on the
project problem explicitly, the boundary of the project had to also be
defined and clearly indicated. This research was set to experiment solely
with the gloves of Medium (M) size. The improvement team and
organisation decided to initially focus on this particular product not only
due to this size had historically had the highest number of rejected
products but also the largest orders from customers.
8/10/2019 Lean Six Sigma-End Sem
16/26
8/10/2019 Lean Six Sigma-End Sem
17/26
2. Measure
8/10/2019 Lean Six Sigma-End Sem
18/26
8/10/2019 Lean Six Sigma-End Sem
19/26
3. Analyze
8/10/2019 Lean Six Sigma-End Sem
20/26
8/10/2019 Lean Six Sigma-End Sem
21/26
4. Improve
SCREENING OF FACTORS
DOE & ANOVA TABLE
CRITICAL FACTORS: Oven temperature
Conveyor Speed
Four different ranges of temperatures; 220c, 225c, 230c and 235c andfour distinct speeds; 600, 650, 700 and 750 RPM
8/10/2019 Lean Six Sigma-End Sem
22/26
8/10/2019 Lean Six Sigma-End Sem
23/26
Performance improved with new parameters.
8/10/2019 Lean Six Sigma-End Sem
24/26
5. CONTROL
The aim of the control phase is to sustain the gains from processes
which have been improved by institutionalizing process or product
improvements and controlling ongoing operations . However, due to time
limitation, this stage is still under implementation at the Thai rubber
gloves manufacturing organisation studied in this paper.
8/10/2019 Lean Six Sigma-End Sem
25/26
References
http://iieom.org/ieom2012/pdfs/
http://academic.uprm.edu/ispeprsc
http://www.c4c.ltd.uk/docs/Lean_Presentations
http://www.gdufs.biz/lean-six-sigma-
research-and-practice.pdf
http://iieom.org/ieom2012/pdfs/http://academic.uprm.edu/ispeprschttp://www.c4c.ltd.uk/docs/Lean_Presentationshttp://www.c4c.ltd.uk/docs/Lean_Presentationshttp://www.gdufs.biz/lean-six-sigma-research-and-practice.pdfhttp://www.gdufs.biz/lean-six-sigma-research-and-practice.pdfhttp://www.gdufs.biz/lean-six-sigma-research-and-practice.pdfhttp://www.gdufs.biz/lean-six-sigma-research-and-practice.pdfhttp://www.gdufs.biz/lean-six-sigma-research-and-practice.pdfhttp://www.gdufs.biz/lean-six-sigma-research-and-practice.pdfhttp://www.gdufs.biz/lean-six-sigma-research-and-practice.pdfhttp://www.gdufs.biz/lean-six-sigma-research-and-practice.pdfhttp://www.gdufs.biz/lean-six-sigma-research-and-practice.pdfhttp://www.gdufs.biz/lean-six-sigma-research-and-practice.pdfhttp://www.gdufs.biz/lean-six-sigma-research-and-practice.pdfhttp://www.gdufs.biz/lean-six-sigma-research-and-practice.pdfhttp://www.gdufs.biz/lean-six-sigma-research-and-practice.pdfhttp://www.c4c.ltd.uk/docs/Lean_Presentationshttp://www.c4c.ltd.uk/docs/Lean_Presentationshttp://academic.uprm.edu/ispeprschttp://iieom.org/ieom2012/pdfs/8/10/2019 Lean Six Sigma-End Sem
26/26