Application of Lean Six Sigma for sustainable maintenance: case study

Antosz, Katarzyna; Jasiulewicz-Kaczmarek, Małgorzata; Waszkowski, Robert; Machado, J

doi:10.1016/j.ifacol.2022.09.204

Cited by 7 publications

(3 citation statements)

References 20 publications

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“…Furthermore, when increasing the efficiency and effectiveness of productive processes or services is a constant objective of productive companies (Rojas-Martínez et al, 2020). Therefore, it becomes necessary to eliminate unexpected defects that generate excessive costs and production losses (Antosz et al, 2022), highlighting that these failures can be reduced by improving production system processes (Sharma et al, 2019a). Now, quality in products and services refers to conformity with established standards and specifications, as well as the ability to consistently and efficiently meet the needs and expectations of customers (Martin et al, 2020(Martin et al, , 2021.…”

Section: Introductionmentioning

confidence: 99%

Performance of a concurrent parallel production system through new operating curves of Six Sigma metrics

Fontalvo Herrera,

Banquez Maturana,

Mendoza Villero

2024

Prod.

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Paper aims: This research establishes a method to evaluate a concurrent production system in parallel, through new operating curves of six sigma metrics.Originality: Se proposes a novel method that provides criteria to monitor the performance of a production system in changing production conditions.Research method: This research was approached from a logical positivist epistemological model, through a heuristic analysis and with a rational propositional approach to establish the characterization of the model, the evaluation metrics and propose the new operation curves. Main findings:The results obtained show that as the sigma level increases in the global system (4.17), the level of defects per million opportunities decreases considerably and the performance increases at levels close to the main objective of Six Sigma, all this with a decrease of defects from 20.657 to 1.317, generating a high quality of 99.99% and achieving a good performance according to the established quality criteria. Implications for theory and practice:This research provides a new tool where they articulate concepts of six sigma and operating curves to monitor a productive system, which allows in a practical way to determine the real capabilities in terms of quality performance of a system.

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Section: Introductionmentioning

confidence: 99%

Performance of a concurrent parallel production system through new operating curves of Six Sigma metrics

Fontalvo Herrera,

Banquez Maturana,

Mendoza Villero

2024

Prod.

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“…Lean Six Sigma in conjunction with quality tools can improve any activity or process, one example of this is the study of Antosz et al [19] which carried out in a floor covering company. They apply the DMAIC methodology and Total Productive Maintenance (TPM) to improve the efficiency and effectiveness of the maintenance process, as well as increase the operational availability of the machines.…”

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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“…The hybrid LSS methods were rarely used in previous dairy studies. However, the DMAIC-TPM hybrid model was used to achieve high process performance and overall equipment effectiveness in manufacturing industry (Antosz et al , 2022). Despite the DMAIC-TPM model provided a good framework and methodology to improve the maintenance performance continually, the actions implemented in one company were difficult to use in modelling of total maintenance in other industries requiring more data and future model validation.…”

Section: Introductionmentioning

confidence: 99%

Utilising a hybrid DMAIC/TAM model to optimise annual maintenance shutdown performance in the dairy industry: a case study

Trubetskaya,

Ryan,

Powell

et al. 2023

IJLSS

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Purpose Output from the Irish Dairy Industry has grown rapidly since the abolition of quotas in 2015, with processors investing heavily in capacity expansion to deal with the extra milk volumes. Further capacity gains may be achieved by extending the processing season into the winter, a key enabler for which being the reduction of duration of the winter maintenance overhaul period. This paper aims to investigate if Lean Six Sigma tools and techniques can be used to enhance operational maintenance performance, thereby releasing additional processing capacity. Design/methodology/approach Combining the Six-Sigma Define, Measure, Analyse, Improve, Control (DMAIC) methodology and the structured approach of Turnaround Maintenance (TAM) widely used in process industries creates a novel hybrid model that promises substantial improvement in maintenance overhaul execution. This paper presents a case study applying the DMAIC/TAM model to Ireland’s largest dairy processing site to optimise the annual maintenance shutdown. The objective was to deliver a 30% reduction in the duration of the overhaul, enabling an extension of the processing season. Findings Application of the DMAIC/TAM hybrid resulted in process enhancements, employee engagement and a clear roadmap for the operations team. Project goals were delivered, and original objectives exceeded, resulting in €8.9m additional value to the business and a reduction of 36% in the duration of the overhaul. Practical implications The results demonstrate that the model provides a structure that promotes systematic working and a continuous improvement focus that can have substantial benefits for wider industry. Opportunities for further model refinement were identified and will enhance performance in subsequent overhauls. Originality/value To the best of the authors’ knowledge, this is the first time that the structure and tools of DMAIC and TAM have been combined into a hybrid methodology and applied in an Irish industrial setting.

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Application of Lean Six Sigma for sustainable maintenance: case study

Cited by 7 publications

References 20 publications

Performance of a concurrent parallel production system through new operating curves of Six Sigma metrics

Performance of a concurrent parallel production system through new operating curves of Six Sigma metrics

Powder Detergent Packaging Line Improvement by Lean Six Sigma DMAIC Methodology

Utilising a hybrid DMAIC/TAM model to optimise annual maintenance shutdown performance in the dairy industry: a case study

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