Implementation of Lean Manufacturing to Reduce Hold Types of Mission Case Products using DMAIC and KAIZEN Approach

Kholil, Muhammad

doi:10.54756/ijsar.2023.v3.2.4

Cited by 3 publications

(3 citation statements)

References 22 publications

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“…Data collection was carried out every working day for three months (from February 2022 to April 2022) in the instant noodle production process. This research process follows the DMAIC (Define, Measure, Analyze, Improve, Control) stages, referencing Kholil (2023) and Hendy (2015) for problem-solving and process improvement.…”

Section: Methodsmentioning

confidence: 99%

Quality Control Analysis to Reduce Instant Noodle Product Defects with Six Sigma and Kaizen Method

2023

Nusantara Science and Technology Proceedings

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PT. XYZ is a company operating in the food industry, with its main product being instant noodles. In its production process, not all products produced meet the quality standards set by the company. This indicates the presence of defective products, often due to errors in factors such as machinery or human resources, among others. Initial observations reveal that there are still many defects in their products. Quality control at PT. XYZ is done manually by the owner, who supervises each production cycle. Defects in PT. XYZ's products are categorized into three types: torn noodle packaging, crushed noodles, and torn seasoning packaging. Therefore, improvements are needed in the production of instant noodles by PT. XYZ. This research aims to improve the quality of production in the company and to explain the approach to analyzing the defect rate of instant noodles using Six Sigma and Kaizen. The results obtained using the Six Sigma method in the DMAIC analysis (Define, Measure, Analyze, Improve, Control), showed that product quality testing during the instant noodle production process resulted in 3238 failures. The Defects Per Million Opportunities (DPMO) value was 41172.88, which, when converted to a sigma level, was 3.23, indicating that the sigma level was at the industry average in Indonesia. This suggests that there is a potential for 41172.88 defects per one million productions, showing an inconsistent pattern of DPMO and sigma achievement. This indicates that the production process has not been managed accurately and requires improvement, particularly in the quest for zero defects.

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Section: Methodsmentioning

confidence: 99%

Quality Control Analysis to Reduce Instant Noodle Product Defects with Six Sigma and Kaizen Method

2023

Nusantara Science and Technology Proceedings

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“…It is a continuous improvement philosophy which leads to incremental enhancements in productivity, quality and efficiency while fostering a culture of employee engagement and empowerment. Furthermore, Kaizen is a continuous improvement effort that involves everyone to achieve the goals or goals that have been set by top management in the company (Kholil, 2023). The Kaizen approach promotes the improvement of productivity and contributes to the reduction of defects by certain units (Quddus and Ahsan, 2014).…”

Section: Background 21 Lean Managementmentioning

confidence: 99%

Impact of lean management on work safety and operational excellence within Tunisian companies

Alguirat,

Lehyani,

Zouari

2023

IJLSS

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Purpose Lean management tools are becoming increasingly applied in different types of organizations around the world. These tools have shown their significant contribution to improving business performance. In this vein, the purpose of this paper is to examine the influence of lean management on both occupational safety and operational excellence in Tunisian companies. Design/methodology/approach A survey was conducted among Tunisian companies, and it resulted in the collection of 62 responses that were analyzed using the software SPSS. In addition, a conceptual model linking the practices of the three basic concepts was designed to highlight the hypotheses of the research. Subsequently, factor analysis and structural equation method analysis were conducted to assess the validation of the assumptions. Findings The results obtained have shown that lean management has a significant impact on occupational safety. Similarly, occupational safety has a significant impact on operational excellence. However, lean management does not have a significant impact on operational excellence. Originality/value This work highlighted the involvement of small and medium-sized enterprise’s managers from emerging economies in the studied concepts’ practices. Likewise, it testified to the impacts of lean management on occupational safety and operational excellence in the Tunisian context.

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“…Quality standards include raw materials, production processes and finished products. (23)(24)(25)(26)(27)(28)(29)(30)(31)(32)(33)(34)(35)(36)(37)(38). This Oil and Gas Manufacturing Company was initially involved as an Indonesian supplier in the oil and gas industry.…”

Section: Introductionmentioning

confidence: 99%

Implementation of Lean Manufacturing for Improvement of Gas Pipe Product Quality with Six Sigma Approach andValue Stream Mapping in Oil and Gas

Kholil¹

2023

IJSAR

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A company in the oil and gas manufacturing industry produces gas pipe products using the Polyethylene model. During the period of January to June 2020, the company experienced a defect rate of 2% in the total production. This research utilized a descriptive method to analyze the production process in order to identify and eliminate the rejected products. The objective of this study was to achieve a decrease in defects below 2%. By applying the Six Sigma (DMAIC) method and conducting calculations and analysis, an improvement proposal was developed to address the defects found during the Radiography Test. The proposed solution involves providing specialized training for workers, implementing clear procedures and methods for work, and conducting training sessions to enhance operator skills and understanding of Standard Operating Procedures (SOPs). As a result of the proposed improvements, a comparison of cycle times was conducted. Prior to the implementation of the improvements, the cycle time was 390 minutes. However, after the implementation, the cycle time reduced significantly to approximately 245 minutes. Overall, the proposed improvements aim to reduce the defect rate below 2% and optimize the production process for gas pipe products with the Polyethylene model in the oil and gas manufacturing company.

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Implementation of Lean Manufacturing to Reduce Hold Types of Mission Case Products using DMAIC and KAIZEN Approach

Cited by 3 publications

References 22 publications

Quality Control Analysis to Reduce Instant Noodle Product Defects with Six Sigma and Kaizen Method

Quality Control Analysis to Reduce Instant Noodle Product Defects with Six Sigma and Kaizen Method

Impact of lean management on work safety and operational excellence within Tunisian companies

Implementation of Lean Manufacturing for Improvement of Gas Pipe Product Quality with Six Sigma Approach andValue Stream Mapping in Oil and Gas

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