IMPLEMENTATION OF LEAN–SIX SIGMA TECHNIQUES IN A MANUFACTURER OF BINDERS (original) (raw)

A Content Analysis on Lean Manufacturing -Concept and Benefits for Manufacturing Industry

IJRASET, 2021

Nowadays, every organization must be required to determine its strength and weaknesses to enlarge productivity and output of their operations. The concept of lean production system has been acknowledged as a means to increase competitiveness for manufacturing concerns all over the world. The present paper has been planned to analyze the concept of Lean Production and its benefits for manufacturing industries. On the basis of the content analysis, the study found that lean manufacturing is gaining popularity day by day among manufacturing industries due to its potential of increasing operational performance. This is done with the help of its set of tools and principles which are used in the systematic elimination of seven wastes, namely, overproduction; waiting; scrap; conveyance; processing; inventory; and motion. Elimination of wastes enable manufacturer to produce the product with superior quality, lower cost and on time with lesser efforts.

Improving Manufacturing Efficiency and Effectiveness Using Lean Six Sigma Approach

International journal of technology and engineering studies, 2022

Success of any organization is directly related to how effectively it implements continuous improvement methodologies. Lean Six Sigma (LSS) is a continuous improvement approach that aims to improve process efficiency and effectiveness. This study explores the latest developments, current trends and perspectives of LSS in the manufacturing sector. LSS critical success factors (CSFs) in manufacturing are discussed. The results of this study revealed the most important contributions in terms of publications, authors, countries, application, objectives and LSS tools. The results found that, applying LSS approach can improving quality, reducing process variation, eliminating waste, improving production rate, improving process productivity, reducing cycle time, reducing non-value-added time, reducing lead time, and reducing production cost. Which lead for reducing unit price and increasing customer satisfaction. Furthermore, the results can be used for a systematic literature review by researchers and manufacturing leaders before embarking on a continuous improvement journey. Finally, an integrated LSS-DMAIC framework is developed for improving manufacturing efficiency and effectiveness.

Understanding the Need of Implementation of Lean Techniques in Manufacturing Industries: A Review

International Journal of Trend in Scientific Research and Development (IJTSRD), 2019

In competitive environment lean manufacturing is necessary in every industry. Lean production is a standard manufacturing mode of the 21st century All the manufacturing industries have put a continuous efforts for its survival in these current world. In order to handle the critical situations manufacturers are trying to implement new and innovative techniques in their manufacturing process. Later on lean was formulated and developed as the solution to the fluctuating and competitive business environment. Due to rapid change in business environment the manufacturing organization are forced to face challenges and complexities in the competition. The concept of lean manufacturing was developed for maximize the resource utilization and minimize the wastes. The main focus of the lean manufacturing is to satisfy customer demands for high quality and low cost. The technique not only identifies the reasons for waste but also helps in its removal through marked principles and guidelines. Lean Manufacturing is an efficient and fast growing approach in the world of competition. Lean manufacturing utilizes a wide range of tools and techniques; the choice of tools is based on the requirement. Many parameters contribute success of lean. Organizations which implemented lean manufacturing have higher level of flexibility and competitiveness. However, lean manufacturing provides an environment that is highly conducive to waste minimization. The majority of the study focuses on single aspect of lean element, only very few focuses on more than one aspect of lean elements, but for the successful implementation of lean the organization had to focuses on all the aspects such as Value Stream Mapping (VSM), Cellular Manufacturing (CM), U-line system, Line Balancing, Inventory control, Single Minute Exchange of Dies (SMED), Pull System, Kanban, Production Leveling etc.,

Lean Manufacturing: An Approach for Waste Elimination

International Journal of Engineering Research and, 2015

Lean Manufacturing (LM), a manufacturing system and philosophy, was originally developed by Toyota, Japan and is now widely practiced by many manufacturers throughout the world. Lean manufacturing is a systematic approach to identifying and reducing waste (non value-added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection. LM is important, primarily because of waste reduction and reduction in lead time. The objective of this paper is to identify Lean manufacturing practices in small scale industries. For this purpose some case studies were chosen and critical observations are identified. Some of these annotations are improper utilization of resources, quality tools for improvements and improper plan for location and layout. This paper includes one case study with the initiatives, observations, results and conclusions of the study carried out in a small scale industry.

Lean Six Sigma Methodology and Its Application in the Manufacturing Industry – A Review

American Journal of Mechanical and Industrial Engineering

This paper reviewed and analyzed literature on lean six sigma (LSS) methodology tools and its applications in the manufacturing industries. Lean manufacturing deals with the process improvement and effective productivity of an organization through elimination of waste. Six sigma on the other hand, is a concept of improving plan that is capable to reduce process/operation variation of an organization. The lean-six-sigma has been practiced mostly in the developed countries along organization of time, but its importance both in the manufacturing processes and management activities cannot be neglected. The aim of this paper is to highlight the benefits of these concepts and how the two principles are merged in industries to improve productivity effectively, reduce waste, and increase the product quality level as well as ensure customer/stakeholder satisfaction. The paper also discussion various lean six sigma methodology tools adopted by small and medium scale industries to achieve improved product quality level and process or operation efficiency. This lean-six-sigma can be implemented or applied to any kind of industry for better productivity through continuous improvement on the business activities. This study would help any kind of manufacturing industry to find a solution on how to compete favorably in a competitive business environment with a dynamic market system and also equally be used by other researchers to enhance their literature.

Literature Review on Implementation of Lean Manufacturing Techniques

International Journal of Advance Research, Ideas and Innovations in Technology, 2015

In competitive environment lean manufacturing is necessary in every industry. Lean production is a standard manufacturing mode of the 21st century. Lean manufacturing have various synonyms like lean management, lean production, It is very use full techniques for reduce the flow of non value added time. Lean manufacturing is a philosophy to reduce the time between customer order and products are ready for the delivery by eliminating waste. Waste (muda) is a serious problem in to the industry it is creates a non value added services and poor quality of the product. Waste are seven type occurs in industry 1) transport,2) inventory,3)motion,4) waiting,5) over production,6) over processing,7) defect. It is eliminate with the help of lean manufacturing. It is an integrated system that gives production of goods/services with minimum buffering costs. This paper gives the literature survey on various type of industry to apply the lean manufacturing, like apply in to automobile industry, and ...

APPLICATION OF LEAN AND SIX SIGMA TOOL TO WASTE REDUCTION IN INDUSTRIES

With rising environmental concerns from consumers to stakeholder’s groups, environmental management has become an important responsibility for today’s manufacturers. It’s no surprise people are always looking for products that leave a minimal environmental impact. Thus less thought and hard analysis has been given to develop a logical operational approach that can be used to minimize environment and that also makes sense from a business perspective. In this paper concern has been put on Food and Drink industries. This manuscript assesses the current operational and management practices of these industries. Studies focusing on waste across the supply chain. Data were collected through reviewing different manufacturing processes. The Data collected and supplementary documentation were analyzed using Value Stream Map. Applying Lean Six Sigma (LSS) methodology and waste management in the food and drink industry leads to many of the improvements demonstrated in other sectors-energy efficiency, reduction of raw material use, reduction in water consumption and increasing reuse and recycling on site. Such improvements in environmental performance produce a directly beneficial effect on the profitability of business. It is to be noted the literature doesn’t involve an in-depth case study of six sigma rather involves the use of lean and six sigma in processes.

Lean manufacturing – results of selected implementation projects

Journal of Intercultural Management, 2013

Lean Manufacturing is a structured program whose objective is to maximize the effectiveness of the company. It is based on the practices and methods of KAIZEN / LEAN applied by the world’s best companies. The experiences from the Author led us to the conclusion that the Lean Manufacturing is based , among others, on the following concepts: - Total Productive Maintenance TPM - Single Minute Exchange Die SMED The Lean Manufacturing focuses on the systematic pursuit and elimination of waste and losses. The losses identified are analyzed, evaluated in adequate manner to the attribute processes. The result of the analysis determines where and how to intervene. In the paper has been presented the bases of Lean Manufacturing. The results of the implementation of Lean Manufacturing in different companies have been described. The main issues of Lean Manufacturing implementation have been characterized.

Lean Manufacturing Practices - a Literature Review

International Journal of Advance Engineering and Research Development

Survival of any industry in this era of globalization & a cut-throat competition becomes extremely difficult. In order to survive, it is necessary to adapt to this ever changing environment. Globalization has made this competition fierce & has also helped in developing techniques & methods that are exceedingly helpful for any industry to flourish even in today's times. Lean is one such tool that can be applied anywhere & everywhere in industry. From shop-floor to the top management, lean has proved its mettle. Application of lean reduces the wastes that are produced & also helps in streamlining the production system. It focuses on continuous improvement & at the same time reducing the wastage. Widely used techniques like Kaizen, 5S, Six Sigma, Value Stream Mapping (VSM) are a part of lean. Implementation of lean leads to all around development of any industry. This paper discusses comprehensive literature on implementation of lean manufacturing. The case studies considered in this paper includes work of international researchers.

A LEAN SIX-SIGMA MANUFACTURING PROCESS CASE STUDY

Lean Six-Sigma – LSS manufacturing floor. Initiated in the automotive industry, continuous improvement were implemented to improve the manufacturing process change. LSS elaborate a case where lean process. Benefits of LSS are to process inventory. Six-sigma focuses on process flow and pressure variations. Value Stream Mapping to reveal problems lean, such as describes all activity of process, Therefore, a new VSM is corrected to redesign a new lean process flow through process improvement with elimination of the root causes of waste. This paper proves the using of LSS principles and