Adopting Lean Six Sigma to AnyLogic Simulation in a manufacturing environment

Abstract

The aim of this paper is to illustrate the use of the Lean Six Sigma (LSS) methodology in a manufacturing environment by adopting the simulation software Anylogic®. In doing so, we present an innovative approach that implements simulation as a decision-supporting tool in the management of Six Sigma quality improvement projects. We intend to demonstrate how the LSS improvement process, "Define, Measure, Analyse, Improve & Control" (or DMAIC) can be applied in the Anylogic® environment so as to enable us to validate a manufacturing system's existing state and its subsequent improvement. LSS has become the de-facto method for process performance improvement in manufacturing sectors and LSS has been progressively increasing its acceptance in industrial manufacturing that confronts challenges, such as, how to decrease waiting time, maximise capacity, best use resources etc. Determining what alterations and changes to make is not simple and it is not easy to forecast the effect of proposed changes precisely. Coping with complicated systems composed of several interacting components poses the risk of generating s unacceptable decisions. This paper explains how the simulation program Anylogic®, with its powerful predictive and visualization capabilities reduces the risk of making undesirable process improvement decisions and assists in ensuring the best possible solutions are found and executed. Consequently, the quality of any process may be enhanced by utilising Lean Six Sigma in an Anylogic Simulation environment and it has the potential to offer a useful approach in term of improving quality and reducing costs. This approach enables evaluation of the performance of the manufacturing process after the proposed and recommended solutions for waste reduction have been implemented. Anylogic® can confirm improvements in yield, Defects Per Million Opportunities (DPMO) and six sigma levels.