Abstract
In today’s global economy, the introduction of new methods, designs, products and processes have been accelerating in geometric progression due to changing consumers’ needs in the face of global competitions and technological advancement in product development. Product development managers and design stakeholders are facing real pressure to continuously adopt new system architecture and operational parameters to remain competitive. The viability of the product development and manufacturing firm now depends largely on how well they are able to respond to these changes in order to meet the customer requirements while becoming lean. The study will also provide a tool for monitoring the relationship between product performance and the Lean Product Development Tool (LPDT). It evaluates the relationship between Maggi spice production, of a Consolidated Foods Limited, in Nigeria and its relationship with DMAIC (Define, Measure, Analyse, Improve and Control) model, a lean six sigma tool, for evaluating root causes of product defects. At the end of the lean implementation, product performance of the pilot line, Omori Line 1 increases from 60% to 76% and a cost savings of NGR 12.03 million were realized at the end of the project.
Highlights
In today’s global economy, the introduction of new methods, designs, products and processes have been accelerating in geometric progression due to changing consumers’ needs in the face of global competitions and technological advancement in product development
This paper examined the relationship between product performance and lean product development tools using DMAIC model
DMAIC Six Sigma methodology, was used to find root causes of high rate of defective Maggi cubes on the Omori Line 1 and proffer solutions to eliminate these defects in order to improve line performance from 60% to 76% and sustain the results achieved through the improve phase
Summary
In today’s global economy, the introduction of new methods, designs, products and processes have been accelerating in geometric progression due to changing consumers’ needs in the face of global competitions and technological advancement in product development. Manufacturing companies and manufacturing stakeholders are facing real pressure to continuously adopt new system architecture and operational parameters to remain competitive [1]. The global market has become extremely competitive and these companies have adopted several lean approaches to achieve minimal defects towards reducing manufacturing cost and optimizing profits. Product development tools normally applied in response to these market trends include the Just-in-time (JIT) technique, which is used for reducing the in-process inventory and associated carrying cost. For the purpose of this study, these tools will be regarded as Lean Product Development Tools (LPDT)
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