APPLICATION OF LEAN AND SIX SIGMA TOOL TO WASTE REDUCTION IN INDUSTRIES (original) (raw)
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Purpose The purpose of this paper is to examine and evaluate various Lean, Six Sigma and Lean Six Sigma (LSS) models proposed by various researchers, which have been implemented in manufacturing organizations. Design/methodology/approach The present study has followed three major steps in methodology. In the first step, pooling of various research articles has been done, followed by development of the primary results. At the final step, analysis and development of the LSS model have been performed. Findings This paper evaluated and examined various models of Lean Manufacturing, Six Sigma and LSS and developed an advanced LSS model that can be deployed in any manufacturing organization with the purpose of scrap reduction. Originality/value The findings of this study will assist shop floor managers to implement an LSS model in their organizations, which can effectively reduce the waste and enhance the overall productivity and quality of the manufactured products.
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Lean Six Sigma and environmental sustainability: the case of a Norwegian dairy producer
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Lean Six Sigma is an approach which focuses on continuous improvement of processes in order to reduce the cost due to poor quality and to make improvements in the bottom line results to create value for the customers. The Basic purpose of this paper is to explore the various critical success and failure factors of LSS approach in various SME's clusters of India. The following research is based upon the systematic literature review of papers published in various reputed journals on techniques like Lean manufacturing, Six Sigma and Lean Six Sigma.
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PT XYZ is a company engaged in the production of pesticides. There are some problems in production process that cause inability to full fill the production quantity target without doing overtime. the problem is the existence of activities that are not value-added and products defect. There are 48,73 % non value added activity and in 2017 the average of products defect reaches 3.89% of total production. This can affect the quality of the products produced to compete with similar companies. This problem is solved by Lean Six Sigma approach. Based on research conducted Lean current condition is PCE (Process Cycle Efficiency) equal to 51,27%, process velocity equal to 0,082 process / hour. The research shows that quality performance at the first phase inspection was 3.77 sigma, on phase II was 3.85σ. The most common product defect is a leaky bottle, an oblique stamp, a torn /wrinkled label and a missing / blurry label. The proposed improvements are the application of the 5S and weighted product method. Based on estimation result, the process cycle efficiency and process velocity was increased to 55.07% and 0.071 process /hour respectively, Quality performance in the inspection phase I is 4.20 σ and on phase II is 4.40 σ.
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In today's fiercely competitive market, maintaining profitability and sustainability is crucial for manufacturing organizations. "Lean and Six Sigma Strategies: Scrap Reduction in Indian SMEs" addresses the pressing issue of financial losses due to scrap in Indian SMEs. The book delves into the critical need for effective waste management techniques to ensure these businesses not only survive, but thrive.This comprehensive guide explores the implementation of Lean and Six Sigma (LSS) methodologies, proven successful in global contexts but underutilized in India. Through extensive research, including literature reviews, surveys, and case studies, the book identifies the best practices for waste reduction. It presents a robust LSS model tailored for Indian SMEs, validated by real-world applications in foundries and auto-component manufacturers. This book is an essential resource for industry professionals and academics, providing actionable insights and a strategic framework for reducing waste and enhancing productivity in small and medium-sized enterprises.
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To survive in the global competitive market, the manufacturing organization must adopt changes in technologies and strategies into their processes on a continuous basis. So, nowadays, Lean, Green, and Six Sigma became business process strategies, which are employed in most of the organization to enhance their manufacturing performance. However, the significant information is that these strategies are implemented sequentially instead of simultaneously. The objective of this chapter is to propose an integrated Lean- Green-Six Sigma strategic framework for manufacturing industries that effectively implementing this approach will lead business processes to achieve operational, financial, social, and environmental growth. This will also guide the practitioner and academician those who are working on manufacturing strategies.