Implementing the Lean Sigma framework in an Indian SME: a case study
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In this article, the authors proposed a Lean-Sigma framework to reduce the defect occurring in the final product (automobile accessories) manufactured by a die-casting process, which integrates Lean tools (current state map, 5S system, and total productive maintenance) within Six Sigma DMAIC methodology to enhance the bottom-line results and win customer loyalty.Abstract:
Lean and Six Sigma are two widely acknowledged business process improvement strategies available to organisations today for achieving dramatic results in cost, quality and time by focusing on process performance. Lately, Lean and Six Sigma practitioners are integrating the two strategies into a more powerful and effective hybrid, addressing many of the weaknesses and retaining most of the strengths of each strategy. Lean Sigma combines the variability reduction tools and techniques from Six Sigma with the waste and non-value added elimination tools and techniques from Lean Manufacturing, to generate savings to the bottom-line of an organisation. This paper proposes a Lean Sigma framework to reduce the defect occurring in the final product (automobile accessories) manufactured by a die-casting process. The proposed framework integrates Lean tools (current state map, 5S System, and Total Productive Maintenance (TPM)) within Six Sigma DMAIC methodology to enhance the bottom-line results and win customer loyalty. Implementation of the proposed framework shows dramatic improvement in the key metrics (defect per unit (DPU), process capability index, mean and standard deviation of casting density, yield, and overall equipment effectiveness (OEE)) and a substantial financial savings is generated by the organisation.read more
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References
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The Machine That Changed the World
TL;DR: A 5-million-dollar 5-year study on the future of the automobile industry was conducted by the Massachusetts Institute of Technology (MIT) as mentioned in this paper, which was based on the International Motor Vehicle Program (IMVP).
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Lean thinking: banish waste and create wealth in your corporation (2nd, revised and updated ed.)
James P. Womack,Daniel T. Jones +1 more
TL;DR: The authors describe in detail how managers in a wide range of companies and industries - small, medium and large, North American, European and Japanese - transformed their business by applying the principles of lean thinking.
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Toyota Production System : Beyond Large-Scale Production
TL;DR: In this paper, Taiichi Ohno shares the genius that sets him apart as one of the most disciplined and creative thinkers of our time, and combines his candid insights with a rigorous analysis of Toyota's attempts at Lean production.
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Lean Thinking: Banish Waste and Create Wealth in Your Corporation
James P. Womack,Daniel T. Jones +1 more
TL;DR: In this paper, Lean thinking is used to eliminate waste and create wealth in a company, with the goal of eliminating waste and creating wealth in the company itself, by eliminating unnecessary resources.