Lean Manufacturing and Six Sigma Principles Implementation in the Industry: Case Study

Abstract

Meeting customer satisfaction is significant for manufacturers to support their company's competitiveness. Different lean tools can enhance manufacturing firm’s capability in the severe competence market. However, integrating lean practices with the six-sigma approach will increase productivity and reduce waste. This research aims to improve the Process Cycle Efficiency (PCE) of the pre-stressed spun concrete pole production at a Private Company. The define-measure-analyze-improve-control (DMAIC) methodology and value stream map (VSM) were used to minimize waste and improve the process. The results show that the highest waste was in work in progress (WIP) inventory. The analysis showed that the manufacturer's push system is not proper for the specific product under investigation. One of the significant outputs of the research is by suggesting using a pull system. Finally, using the Lean Six Sigma approach by DMAIC methodology positively impacts the pole’s PCE. The results show a significant improvement when using the lean six sigma approach.