Production lessening analysis of manufacturing unit in India: Lean Six Sigma perspective

Abstract

Lean Six Sigma is systematic and excellent operation management approach aimed to enhance overall production through the elimination of waste and improve customer satisfaction. In the present case study, automobile part manufacturing unit has been selected and found 22% wastage in manufacturing steps resulting reduction in production. The primary objective of this research is to find the main reasons of production wastage and recommend corresponding remedies to counter the wastage reasons. For this purpose, Lean Six Sigma approach with the help of DMAIC methodology is implemented to observe and examine different root causes of the frame lugs production losses and rejection problems. The result reveals that the movement of material and employee are critical issues for wastage of re-sources, ultimately affecting production of industry. Lastly, the possible solutions are to be advised to tackling these issues. The successful execution of the proposed solutions show 7% growth in the production of the component which saves annually INR 15, 64, 056.