The Lean Six Sigma / LSS approach has received a lot of attention in various industrial sectors, from the manufacturing industry to the service industry. More specific knowledge about Lean Six Sigma has grown rapidly. Much of the training and research on Lean Six Sigma is carried out in various industries. This literature review is related to LSS's purpose to provide an overview of Lean Six Sigma implementation in the manufacturing industry. The Lean Six Sigma approach introduced and implemented for a long time is DMAIC (Define, Measure, Analyze, Improve, and control). This paper discusses the published literature related to Six Sigma ranging from 2015 to 2020. This paper involves the study review of 50 papers related to the implementation of LSS of known database search, including Google Scholar, Elsevier, Science Direct, and other worldwide publishers. This literature review contains results from a variety of different perspectives. The perspective includes the focus of the industry, the focus of the number of distribution by country, the focus of the year of publication, and the number of publishers. This is useful for all types of manufacturing industries to find solutions to problems. The paper also provides advantages for researchers next to add to the literature.
The scope of this research is in one of the textile industries with elastic tape produced on the weaving machine, which has decreased production due to production defects that do not meet the target. This research aims to determine the leading causes of dominant defects, increase the sigma level with Six Sigma methods, and propose improvements to be included in the Key Performance Indicators (KPI) method. The results of this study that the dominant factor causing the defect is the curved elastic tape defect, which consists of the machine factor, and the method. Factors driving the machine include the hook like a side thread lock that is often bent and the difference in the thickness of the tape between the left, middle and right. The causative factor of this method is checking the thickness of the elastic band only in the center position. The results of corrective actions impact increasing the sigma level by 10% from 3.3339 to 3.6832. In contrast, repair defects can reduce defects before repair by 18.92% and after repair by 9.23%. It is proposed to be included in the KPI so that the weaving department can control and be enthusiastic about continuous improvement.
This study aims to implement the Six Sigma method on formal men's jacket products in the garment industry to increase the level of sigma. The methodology is based on the Define, Measure, Analyze, Improve, and Control (DMAIC) approach. The new approach in this study is the determination of 5W+1H using a Focus Group Discussion (FGD) with five expert judgments. The design of this study has applied the Six Sigma method at the Measure stage. It is a measurement before improvement and after the Control stage as a measurement after improvement. The results of this study have increased the level of sigma from 3.5765 to 3.7839, so there is an increase of 5.48%. Increasing the sigma level contributes to a decrease in defects at the finish line by 44.09% every month. Implementing the Six Sigma method to the DMAIC approach has succeeded in increasing the level of sigma, automatically reducing the percentage of defects and increasing the productivity of formal men's jackets in the garment industry.
Purpose: This study aims to analyse the waste in the production line to get an efficient production lead time. Methodology/Approach: This research uses the integration method of value stream mapping and kaizen. Based on the analysis with expert judgment, it is known that the waste comes from an inefficient factory layout. Improvements by making changes to factory layouts and merging workstations. Findings: This research has found waste caused by ineffective factory layouts based on Focus Group Discussions (FGD). Improvements by incorporating workstations and changes to the factory layout can reduce production lead time. The results showed that the production lead time decreased from 3.21 days to 2.31 days or a decrease in the ratio of 31.15%. Research Limitation/Implication: This research can also improve manufacturing performance such as cost efficiency, efficient layout, and labour reduction. So for similar companies, this research can be a reference for making improvements in reducing waste that can improve manufacturing performance so that they can compete in national and international markets. Originality/Value of paper: This paper provides benefits for the musical instrument industry regarding waste reduction. According to this research, lean production can increase the productivity and quality of the production system, because it can eliminate the waste of time or the production process. The new approach of this research is used the integration methods by involving experts through FGDs to make improvements and reduce waste in the production line.
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