LEAN SIX SIGMA

END-TERM REVIEW

Guided By:
Dr. Abhishek Kumar
Dept. of Industrial Eng.
PDPU

Prepared By:
Deep Dave
Industrial Engineering
11BIE020

INTRODUCTION
Todays manufacturing and business environments are reaching a point
that competition for survival and market share is an obligation.
Tracking the global economy will show that being good is not enough,
therefore each organization really strive for excellence if want to stay in
the market.
Every single organization is looking for one single outcome
PROFIT

 PROFIT is not a single concept but comes with many

important implications:
P- Process excellence
R- Resources Management
O- Oriented to a Goal
F- Financially Strong
I- Innovative to stay ahead of competition
T- Timely deployment of strategies
In order to be a leader, most companies are realizing
that traditional management, manufacturing
processes, and other historic approaches, are not
enough.
More effective methods are needed:
Six Sigma
Lean Manufacturing

Why Lean Six-Sigma?

Lean Management Philosophies

Main Disadvantage of Lean

Management
In LS Profit can not be calculated in monetary value as opposed to Six
Sigma where with the help of Taguchi loss function we can show the
reduction in loss(or gain of profit) in terms of monetary value.

Six Sigma
Six Sigma is one of the most potent strategies ever developed to
accelerate improvements in processes, products, and services, and to
radically reduce manufacturing and/or administrative costs and improve
quality. It achieves this by relentlessly focusing on eliminating waste and
reducing defects and variations.

WHAT Is DMAIC?
DMAIC is the most powerful tool of SixSigma for Continuous improvement.
A logical and structured approach to
problem solving and process
improvement.
An iterative process (continuous
improvement)
A quality tool which focus on change
in management style.

Define

Measure
Control

Analyse
Improve

9
9

Lean Six Sigma

Lean Six Sigma is a methodology that relies on a collaborative
team effort to improve performance by systematically
removing waste; combining lean manufacturing/lean
enterprise and Six Sigma to eliminate the eight kinds of waste
(muda).

Lean Six Sigma- 7 MUDAs

Identify and reduce:
Defects (repair, rework, scrap)
Overproduction (inventory)
Transportation (conveyance)
Waiting (queue time)
Inspection (reliance on mass inspection/
verification)
Motion (parts, paper, people)
Process, itself (over-processing, long cycles)

A Case Study
AIM- Defects Reduction in a Rubber Gloves Manufacturing Process.

1. DEFINE
Voice of the customer (i.e. customer requirements): the problem selected
to be tackled through this project was to reduce/eliminate quality defects
(i.e. holes/stains) on gloves .
In order to ensure that the research is in-control and focuses on the
project problem explicitly, the boundary of the project had to also be
defined and clearly indicated. This research was set to experiment solely
with the gloves of Medium (M) size. The improvement team and
organisation decided to initially focus on this particular product not only
due to this size had historically had the highest number of rejected
products but also the largest orders from customers.

2. Measure

3. Analyze

4. Improve
SCREENING OF FACTORS
DOE & ANOVA TABLE
CRITICAL FACTORS: Oven temperature
Conveyor Speed
Four different ranges of temperatures; 220c, 225c, 230c and 235c and
four distinct speeds; 600, 650, 700 and 750 RPM

 Performance improved with new parameters.

5. CONTROL
The aim of the control phase is to sustain the gains from processes
which have been improved by institutionalizing process or product
improvements and controlling ongoing operations . However, due to time
limitation, this stage is still under implementation at the Thai rubber
gloves manufacturing organisation studied in this paper.

References
http://iieom.org/ieom2012/pdfs/
http://academic.uprm.edu/ispeprsc
http://www.c4c.ltd.uk/docs/Lean_Presentatio
ns
http://www.gdufs.biz/lean-six-sigmaresearch-and-practice.pdf