Lean Six Sigma

About: Lean Six Sigma is a research topic. Over the lifetime, 1919 publications have been published within this topic receiving 29142 citations.

Research on process optimization for equipment maintenance based on lean six sigma management

Abstract: In order to optimize the process of equipment maintenance and improve the maintenance efficiency effectively, by the four steps of choosing the method of DOE, fitting the model, analyzing the residual and optimizing the result, equipment maintenance process optimization model method under equipment maintenance lean six sigma project is established based on design of experiment (DOE). Via taking a certain equipment maintenance technique parameters optimization as an illustrative example, the optimization model which can provide a new method for the optimizing of equipment maintenance process in lean six sigma project is proved to be scientific, valid, and well applicable finally.

An empirical study into the reasons for failure of sustaining operational excellence initiatives in organizations

Abstract: PurposeOperational excellence (OPEX) initiatives such as Lean, Six Sigma, Lean Six Sigma and Agile have some common characteristics that can be understood through their adoption in organizations. The objective of this research is to present the results of an online survey highlighting the most critical reasons for failure of OPEX initiatives.Design/methodology/approachThis study presents the results of a survey from 106 experts from different countries who have been involved in OPEX implementation. The experts were Six Sigma Master Black Belts, Black Belts and Champions from different manufacturing and service organizations. The developed questionnaire was initially tested with the help of seven experts to ensure their technical validity and soundness.FindingsThe study found 15% of companies surveyed have not adopted any form of OPEX methodology. The top three reasons for non-adoption of OPEX were also found. In terms of the use of various OPEX methodologies, more than 75% of companies were employing Six Sigma and less than 50% were engaged in Lean initiatives. Another surprising result was that less than 5% of the companies were utilizing Kaizen and other continuous improvement methodologies for improving the efficiency and effectiveness of organizational processes. The study further finds top five failure factors for sustaining OPEX initiatives in manufacturing, service, large and small organizations.Research limitations/implicationsThe study reports the outcomes based on an online survey with limited sample size. Moreover, the number of samples from small and medium-sized enterprises (SMEs) was less than 25, and therefore it was difficult to make any robust conclusions in the comparison of failure factors between large enterprises and SMEs.Originality/valueTo the best of the authors’ knowledge, this is the first empirical study that has attempted to explore the reasons for failure of OPEX initiatives. The authors argue that a greater understanding of the reasons for failure of OPEX initiatives can provide an input to develop a framework that can mitigate the failures and costs associated with such failures.

Snider Tire Optimizes Its Customers-Stores-Plants Transportation Network

Abstract: We successfully redesigned the customer-store-plant production transportation network at Snider Tire, Inc. (STI), one of the largest commercial tire and retreading dealers in the United States, in two stages. We first optimized the plants-to-stores networks, and we then reengineered the customers-to-store truck routes. We used a Lean Six Sigma (LSS) and optimization framework to improve key supply chain processes of plants’ capacity planning, and distribution routes optimization by focusing on the root causes of process problems and investigating process alternatives. This approach ensured that managers from this small, privately owned, traditional organization were part of the team that developed the solutions, enthusiastically implemented them, and co-owned them. As a result, STI is saving $2 million (16 percent) in annual transportation costs.

Reviewing the Effects of Integrated Lean Six Sigma Methodologies with Ergonomics Principles in an Industrial Workstation

Abstract: This work presents the importance of a combination of three approaches: the Lean idea of waste to be eliminated, the Six Sigma concept of variance to be reduced, and Ergonomics approaches that play an important role in maintaining workers' productivity. Improper workstation layout conditions lead to excessive stress, reduced performance, and physical burdens. This leads to increases in waste indicators such as loss of time, poor space, and low quality levels. A single-minded focus on productivity may neglect health and safety issues and, worse, changes introduced by Lean may lead to additional risks. Muda is a term in Lean referring to any action or process that doesn't add value within processes, such as physical waste of time or safety violations. Job Rotation as a problem-solving tool refers to the structured interchange of workers between different jobs that are recognised as problem or high-risk jobs. The methodology of this research work proposes an integrated model combining Lean as represented by reducing Muda or waste that does not add value to both process and workers, previewed by means of the DMAIC Six Sigma stages, with job rotation used as an efficient measurement tool to observe jobs that may be identified as overly stressful. A computerised worksheet tool was used to perform a semi-quantitative assessment process for rating a job's Exertion Index (IE), which can be used to determine the best arrangement of Job Rotation schedules. The work aims were: I) Rearrangement of jobs according to risk level of producing non-well-being to reduce additional psychological stress on workers and to II) reflect this by achieving continuous improvement by eliminating waste, decreasing activities that are Non-Values Add, and thereby creating good quality levels. The findings showed enhancement of current safety and productivity levels from evaluating the Exertion Index and swapping some workstations with unacceptable indices. This offered a reduction in physiological strain, stress, and fatigue on various muscle sets. The case study for this research work was implemented in the General Company for Hydraulic Industries/Damper factory.