Lean six sigma implementation, a systematic literature review

Tampubolon, Salmon; Purba, Humiras Hardi

doi:10.4995/ijpme.2021.14561

Cited by 28 publications

(25 citation statements)

References 36 publications

(37 reference statements)

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“…Lean Six Sigma (LSS) methodology, under the canopy of total quality management (TQM), works on principles of customer converging, process-oriented, data-driven processes and breakthrough improvement strategy. Six sigma -DMAIC (Define-Measure-Analyze-Improve-Control) approach works on linking the business and customer needs together for the benefit of continuous improvement concepts (Tampubolon and Purba, 2021). The DMAIC approach is applicable in both service and manufacturing industries, while, in manufacturing industries, the positive impact of adopting LSS is higher and faster than in services ones (Tarimarjoko et al, 2020).…”

Section: Introductionmentioning

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: Introductionmentioning

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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“…There are many cases where the improvement rate is much more significant, but it seems that these cases are not as often. These findings are based on the research of other authors such as [57][58][59][60][61][62][63][64][65][66][67][68]. Based on a comparison of the classical indicators, the change achieved in the process is slightly above average.…”

Section: Discussionmentioning

confidence: 89%

Algorithm for Process Innovation by Increasing Ideality

Sojka

Lepšík

2022

Processes

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Continual efforts to have better processes lead us to search for new ways to improve and innovate. One of the most powerful approaches to innovating technical systems is the TRIZ (Theory of Inventive Problem Solving). TRIZ is, unfortunately, very hard to learn and adequately use. This paper introduces a new comprehensive algorithm for the innovation of processes in production based on TRIZ principles. The Algorithm for Process Innovation by Increasing Ideality (AP3I) helps search for innovative ways to improve or change the process—either the whole process or its segments. Besides the original TRIZ, AP3I is easier to use and might be applied by engineers in industrial practice. On the other hand, results from AP3I are probably weaker compared to full TRIZ. Still, the AP3I can be very helpful in efforts to improve processes and can provide powerful ideas. The overall algorithm is also demonstrated in case studies on processes of packing and assembly.

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“…Six Sigma is a methodology for improving process quality through the systematic use of DMAIC (Define-Measure-Analyze-Improve-Control). Six Sigma deployment necessitates collaborative efforts to regulate and enhance production quality (Tampubolon et al, 2021). Six Sigma implementation aims to improve processes and constantly obtain reliable and consistent outcomes: Six Sigma adoption necessitates the application of tools and procedures to define and evaluate each stage of a process or project.…”

Section: The Approach Of Six Sigma)mentioning

confidence: 99%

Improve Product Quality and Production Process with Integration of Six Sigma and Quality Management System ISO 9001: A Case Study of Bakery Shop in France

Yusof

Lee

2022

IJIM

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This study highlights macarons product research conducted in a bakery shop in France. It is aims to optimize the quality of the macarons products via the integration of Six Sigma and Quality Management System, ISO 9001. To achieve the objective, the study first identifies the primary root cause of product defects. Besides, an alternative standard operating procedure is incorporated with the recommended improvements. The DMAIC approach is emphasized by the Six Sigma approach, which is Define-Measure-Analyze-Improve-Control. According to the data, the cost of poor quality for a month is 34,511.40 Euro. Cracked macarons (53.70%), hollow macarons (16.30%), and no feet macarons (16.10%) are three major critical defects. The macarons product has a Sigma level of 2.50. The parameters proposed in this study are low-level mixing at 80 rpm, 12 minutes of baking time, and 203°c oven temperature to improve the quality of macarons product using the Design of Experiment (DOE) of the Taguchi Method. When the major elements are controlled inside the processes, the company's chances of producing a high-quality product increase significantly. As a result of adopting Six Sigma with Quality Management System ISO 9001 into the macaron manufacturing process, defects costs and rate is expected to be lower.

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Lean six sigma implementation, a systematic literature review

Cited by 28 publications

References 36 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

Algorithm for Process Innovation by Increasing Ideality

Improve Product Quality and Production Process with Integration of Six Sigma and Quality Management System ISO 9001: A Case Study of Bakery Shop in France

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