Combining Lean Concepts &amp;amp; Tools with the DMAIC Framework to Improve Processes and Reduce Waste

Mazen Arafeh

doi:10.4236/ajor.2015.53017

Abstract

Six Sigma DMAIC methodology has been applied to systematically apply lean manufacturing concepts and tools in order to improve productivity in a local company specialized in the manufacturing of safety and fire resistance metal doors, windows, and frames. In-depth analysis of the plant processes unfolded different critical processes, specifically foam injection process and sheet metal cutting process. Throughout the different project phases, various improvements had been implemented to reduce production cycle time from 216 min to 161 min; non-value added activities in the different processes were identified and eliminated. Plant layout and machine reconfiguration reduced backtracking and unutilized space. Percentage of defective doors (needing rework) dropped from 100% to only 15%. The successful implementation of this project is largely due to top management active involvement and participation of workers and operators in all stages of the project. Finally, new policies and mentoring programs are introduced to maintain improvements.

Highlights

Heightened challenges from competitors have prompted many manufacturing firms to adopt new manufacturing approaches
Customers may be classified as internal or external. In this project we focus our attention at the internal customers, more often known as the voice of the employee (VOE) represented by those who work in the company coming from different departments
Cutting Process From the analysis of the data gathered in the measure phase a cause and effect diagram for high offcuts percentage and long cutting time were created as shown in Figure 13 and Figure 14, respectively

Summary

Introduction

Heightened challenges from competitors have prompted many manufacturing firms to adopt new manufacturing approaches. Salient among these is the concept of lean production [1] [2]. How to cite this paper: Arafeh, M. (2015) Combining Lean Concepts & Tools with the DMAIC Framework to Improve Processes and Reduce Waste. The concept of Lean Thinking (LT) developed from Toyota Production System (TPS) involves determining the value of any process by distinguishing valued-added activities or steps from non-value added activities or steps and eliminating waste, so that every step adds value to the process [3]. Lean is about controlling the resources in accordance with the customers’ needs and about reducing unnecessary waste, including the waste of time and material [4]

Objectives

Methods

Findings

Conclusion