Developing a Lean Six Sigma Conceptual Model and Its Implementation: A Case Study

Sodhi, Harsimran Singh; Singh, Davinder; Singh, Bikram Jit

doi:10.26488/iej.12.10.1199

Cited by 5 publications

(3 citation statements)

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“…Hill, (2018), [24] mentioned a LSS framework for maintenance operations to improve effectiveness and suitability. Sodhi, (2019), [59] developed a LSS framework for waste management in a foundry unit to reduce scrap rate and reworking. Silva, (2019), [56] showed a LSS framework for manufacturing to improve process productivity and quality and reduce direct workforce.…”

Section: Literature Reviewmentioning

confidence: 99%

A Systematic Review of Lean Six Sigma in Manufacturing Domain

Gomaa

2023

Engineering Research Journal (Shoubra)

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Manufacturing companies seek to improve competitiveness through continuous improvement in process productivity and product quality using Lean Six Sigma (LSS) methodology, which is a methodology that integrates Lean Manufacturing and Six Sigma strategies, which means that the principles, philosophies and tools of both methodologies are also united in one approach. This systematic review aims to explore the most popular topics within LSS in manufacturing over the past ten years (2014 to 2023), and to identify and analyze any gaps. Results found that LSS helps in improving quality, increasing sigma level, reducing non-added value, increasing productivity, reducing production costs, and improving customer satisfaction. Furthermore, the results can be used for a systematic literature review by researchers and manufacturing leaders before embarking on a journey of continuous improvement. Finally, this study proposed a LSS framework for the manufacturing domain, which includes 40 steps. Various tools like process mapping, KPIs, OEE, sigma level, seven quality control tools, process time analysis, value stream mapping, kaizen, 5S, brainstorming, and standard work have been used at different phases of DMAIC.

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Section: Literature Reviewmentioning

confidence: 99%

A Systematic Review of Lean Six Sigma in Manufacturing Domain

Gomaa

2023

Engineering Research Journal (Shoubra)

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“…A framework of Lean and Six Sigma tools was implemented in the bulb manufacturing firm in India (Trehan et al, 2019), and mentioned reduction in aging failure rate to 0.13% from 9.4% and a commensurate reduction in customer complaints. Sodhi et al (2019) discussed a case Validation of DMAIC based framework study to improve waste management using a theoretical Lean Six Sigma model. The model was designed by reinforcing Lean Manufacturing tools in Six Sigma approach (DMAIC) and implemented the same in foundry industry to reduce variations in processes.…”

Section: Literature Reviewmentioning

confidence: 99%

Development and validation of DMAIC based framework for process improvement: a case study of Indian manufacturing organization

Kumar¹,

Singh²,

Bhamu³

2021

IJQRM

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PurposeThe purpose of this paper is to develop and validate an extended Define-Measure-Analyze-Improve-Control (DMAIC) based framework through a case study of an Indian fasteners manufacturing organization.Design/methodology/approachResearch methodology is established on the development of the existing DMAIC framework through an extensive literature review of 25 LSS/DMAIC based frameworks and discussions held with practitioners. This paper also depicts a case study of Indian manufacturing organization for validation of the developed framework.FindingsThe study proposed an extended DMAIC based framework for effective implementation of Lean Six Sigma (LSS) methodology. Furthermore, this framework has been implemented successfully in the Indian manufacturing organization and showed encouraging results. The in-house rejections of Nut Cylinder Head (NCH) were brought down to 966 from 2910 PPM and sigma level was improved by 0.40. The case organization has achieved significant improvements in the process capability, customer satisfaction, and cost savings of US$ 0.25 million in one financial year. Intangible benefits like improvements in employee's morale, communication, housekeeping and decision-making capabilities were also observed significantly.Practical implicationsThe proposed DMAIC based framework has been implemented successfully in the Indian case organization, and the results will enable the policymakers, specifically practitioners, to strategically leverage the resources for successful implementation of the LSS in healthcare, aerospace, service sectors etc.Originality/valueThis research develops a DMAIC based framework which can be used to implement LSS effectively in different industries. Moreover, the pre (initial/introduction) and post (validation/verification) implementation phase provides the top management, an edge to think strategically into broader improvement areas.

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“…Singh et al (2019), however, contended that LSS utilizes the Six Sigma DMAIC structure as a stage for activities in mix with a Lean standards and devices, thus valuing the DMAIC procedure as a ground-breaking philosophy for LSS ventures. Truth be told, Sodhi et al (2019a) credited the achievement of LSS venture to the executives to the DMAIC technique. Thus, LSS DMAIC procedure expects to be an incredible and fundamental segment of the achievement of LSS ventures, with less significance to its reappearance from its antecedent Six Sigma.…”

Section: Introductionmentioning

confidence: 99%

A conceptual examination of Lean, Six Sigma and Lean Six Sigma models for managing waste in manufacturing SMEs

Sodhi

Singh²,

Singh

2020

WJSTSD

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Purpose The purpose of this paper is to examine and evaluate various Lean, Six Sigma and Lean Six Sigma (LSS) models proposed by various researchers, which have been implemented in manufacturing organizations. Design/methodology/approach The present study has followed three major steps in methodology. In the first step, pooling of various research articles has been done, followed by development of the primary results. At the final step, analysis and development of the LSS model have been performed. Findings This paper evaluated and examined various models of Lean Manufacturing, Six Sigma and LSS and developed an advanced LSS model that can be deployed in any manufacturing organization with the purpose of scrap reduction. Originality/value The findings of this study will assist shop floor managers to implement an LSS model in their organizations, which can effectively reduce the waste and enhance the overall productivity and quality of the manufactured products.

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Developing a Lean Six Sigma Conceptual Model and Its Implementation: A Case Study

Cited by 5 publications

References 0 publications

A Systematic Review of Lean Six Sigma in Manufacturing Domain

A Systematic Review of Lean Six Sigma in Manufacturing Domain

Development and validation of DMAIC based framework for process improvement: a case study of Indian manufacturing organization

A conceptual examination of Lean, Six Sigma and Lean Six Sigma models for managing waste in manufacturing SMEs

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