Entropy-Based Lean, Energy and Six Sigma Approach to Achieve Sustainability in Manufacturing System

Verma, Neha; Sharma, Vinay; Badar, M. Affan

doi:10.1007/s13369-021-05826-x

Cited by 22 publications

(15 citation statements)

References 42 publications

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“…A recent work by Mohan et al (2021) presents an analysis of researches on GLSS through focusing on systematic literature review to prepare organizations for the application of sustainable GLSS practices through detailed conceptualization and realization. In the same line of research, Verma et al (2021) also propose a value stream mapping (VSM) model that combines lean, energy and six sigma. The proposed model identifies value adding and non-value adding activities via a lean VSM.…”

Section: Previous Studiesmentioning

confidence: 99%

A case study on implementing Lean Six Sigma: DMAIC methodology in aluminum profiles extrusion process

Araman¹,

Saleh

2022

TQM

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PurposeThis paper aims to investigate the sources of variation in aluminum profiles hot extrusion process for the purpose of process capability improvement at National Aluminum and Profiles Company (NAPCO) in Palestine. The critical-to-quality characteristics (CTQ) have been determined as base variables to measure the process capability.Design/methodology/approachThe DMAIC (Define, Measure, Analyze, Improve, and Control) Lean Six Sigma (LSS) approach has been adopted to conduct this study. More specifically, historical data analysis and PARETO charts have been employed. The defects' root causes have been determined using the cause-and-effect diagram and decision matrix. A course of suggested actions has been established to help in improving extrusion process capability. Minitab-18 software was used for conducting inferential statistical analysis. A case study considering a geometry CTQ of D3 dimension of bottom sash aluminum profiles 4,332 was selected for analysis.FindingsThe results indicated a reduction in DPMO from 89,649 to 15,659, sigma level was improved from 2.84 to 3.65, process yield was improved from 91.04% to 98.43% and cost was reduced from U$75,972 to U$13,250.9 (i.e. a saving of U$62,721). Studying and improving the sigma level of the extrusion process would yield fewer defective products and consequently fewer customer complaints. A validation process which has been conducted during the year 2019 showed a consistent improvement that aligns with the first stage of improvement made on October 1, 2018.Research limitations/implicationsThis study focuses on only one critical quality characteristic (CTQ), namely, a geometry CTQ of D3 dimension of bottom sash aluminum profiles 4,332 produced by NAPCO was selected for analysis.Practical implicationsThis study would be useful for researchers and practitioners to improve the process capability in aluminum profiles manufacturing industries in general and hot extrusion processes in particular.Originality/valueMany previous studies on applying LSS-DMAIC methodology have been conducted in aluminum industries in developed countries. According to the literature, it is highly recommended to have more case studies of applying LSS-DMAIC in different industries in developing countries. NAPCO is the only aluminum manufacturing plant in Palestine that hotly extrudes and coats aluminum profiles. Hence, the present study is the first of its kind in NAPCO and in Palestine. Projecting the assessment of the impact of process improvement opportunities and capability analyses into monetary measures are also innovative.

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Section: Previous Studiesmentioning

confidence: 99%

A case study on implementing Lean Six Sigma: DMAIC methodology in aluminum profiles extrusion process

Araman¹,

Saleh

2022

TQM

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“…However, Dinis-Carvalho et al (2019) consider that VSM also has certain limitations, such as: inability to represent different flows; difficulty levels for those who are un-familiar with the tool; absence economic indicators; and absence of layout representation; among others. Verma et al (2021) proposes a new VSM by combining lean, energy and six-sigma methodologies and using the value-added and non-value-added approach to determine…”

Section: Value Stream Map From the Customer's Perspectivementioning

confidence: 99%

“…Verma et al (2021) proposes a new VSM by combining lean, energy and six-sigma methodologies and using the value-added and non-value-added approach to determine energy use and waste. Additionally, a mathematical model is developed to identify rejects or rework at a manufacturing workstation.…”

Section: Literature Reviewmentioning

confidence: 99%

Value stream mapping from the customer's perspective: expanding concepts, representations and key performance indicators based on a typical real case study

ARAGÃO

Jardim

Marujo

2022

IJLSS

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Purpose This study aims to improve the buying experience for both customers and providers by presenting a conceptual basis which seeks to expand the usual understanding, representation, mapping and measurements of the different value and non-value stages of a customer purchase journey (CPJ). Design/methodology/approach Inspired by the precepts of lean thinking, with emphasis on the value stream mapping method, the approach is based on an in-depth analysis of a real and typical e-commerce acquisition of an electronic customised product (a mobile phone) during the COVID-19 pandemic. Findings This study demonstrates different types of consumer stages, values and wastes for the CPJ. This allowed the development of a mathematical formulation – named customer journey engineering (CJE) – from which improvements of the different categories can be identified. Exemplifying with those whose implementations require no further efforts or costs, the following results could be readily obtained in the case studied: a reduction of 96 h of non-value activities, an improvement of approximately 15% of the established index for customer satisfaction and avoidance of loss worth US$50 for the analysed customer. Research limitations/implications The consistency and applicability of the qualitative and quantitative findings presented here should be examined further in other customer purchase scenarios, allowing enhancements of the CJE approach. Originality/value Regardless of the context in question, this investigation attempts to identify and precisely define any common universal elements, often overlooked, which constitute the structure of any CPJ and are crucial for its understanding and improvement.

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“…Organizations suffer from various types of wastes that have differing levels of occurrence (Douglas et al, 2015). If we consider the impact of various forms of VSM tools (see Table 1), it would be effective in eliminating all the wastes completely (Bader et al, 2020) by implementing all these VSM tools instead of just enacting a single LVS (Verma et al, 2021). Records all details of each process and analyzes the flow to reduce unnecessary process activities, combine and simplify tasks and make the sequence of processes most effective 2 Supply chain response matrix (SCR) A simple diagram shows the cumulative inventory versus process lead time for various stages.…”

Section: Introductionmentioning

confidence: 99%

A hybrid approach to enhancing the performance of manufacturing organizations by optimal sequencing of value stream mapping tools

Kumar

Marawar

Soni

et al. 2023

IJLSS

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Purpose Lean manufacturing (LM) is prevalent in the manufacturing industry; thus, focusing on fast and accurate lean tool implementation is the new paradigm in manufacturing. Value stream mapping (VSM) is one of the many LM tools. It is understood that combining LM implementation with VSM tools can generate better outcomes. This paper aims to develop an expert system for optimal sequencing of VSM tools for lean implementation. Design/methodology/approach A proposed artificial neural network (ANN) model is based on the analytic network process (ANP) devised for this study. It will facilitate the selection of VSM tools in an optimal sequence. Findings Considering different types of wastes and their level of occurrence, organizations need a set of specific tools that will be effective in the elimination of these wastes. The developed ANP model computes a level of interrelation between wastes and VSM tools. The ANN is designed and trained by data obtained from numerous case studies, so it can predict the accurate sequence of VSM tools for any new case data set. Originality/value The design and use of the ANN model provide an integrated result of both empirical and practical cases, which is more accurate because all viable aspects are then considered. The proposed modeling approach is validated through implementation in an automobile manufacturing company. It has resulted in benefits, namely, reduction in bias, time required, effort required and complexity of the decision process. More importantly, according to all performance criteria and subcriteria, the main goal of this research was satisfied by increasing the accuracy of selecting the appropriate VSM tools and their optimal sequence for lean implementation.

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Entropy-Based Lean, Energy and Six Sigma Approach to Achieve Sustainability in Manufacturing System

Cited by 22 publications

References 42 publications

A case study on implementing Lean Six Sigma: DMAIC methodology in aluminum profiles extrusion process

A case study on implementing Lean Six Sigma: DMAIC methodology in aluminum profiles extrusion process

Value stream mapping from the customer's perspective: expanding concepts, representations and key performance indicators based on a typical real case study

A hybrid approach to enhancing the performance of manufacturing organizations by optimal sequencing of value stream mapping tools

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