Productivity improvement of highway engineering industry by implementation of lean six sigma, TPM, ECRS, and 5S: A case study of AAA Co., Ltd.

Abstract

Purpose: The objective of this study is to improve productivity by means of lean six sigma, TPM, ECRS, and 5S in the highway engineering industry. The study was conducted from November 2017 to April 2018 from a case study of AAA Co., Ltd. The data were collected from the managers and supervisors and the problems were analyzed by brainstorming, cause and effect diagram, and Pareto chart. Referring to the results, it was found that production problems occurred from the asphalt process. The majority problem was wet rock and rock sticking to the conveyor belt. Methodology: Considering the shed, the shed of stone storage could be changed from construction from net or fabric sieve to construction from the metal sheet. Regarding the conveyor belt, the conveyor belt could be changed from conveyor belt without roof to constructed conveyor roof from metal sheet. The messy construction area was improved by 5S. Essential materials and equipment were sorted in construction area, while the other remained materials and equipment were removed to another area. Main Findings: The findings demonstrated that Lean Six Sigma, ECRS, TPM, and 5S can be seen as an effective technique that can reduce waste and improve business performance which can be applied in any industry as well as any size of the company. It very well may be viewed as the advancement of the improvement strategies among the representatives and as a preparation technique for the workers. The discoveries illustrated, in any case, that there are snags in the viable execution of the improved methods for any improvement reason. Implications/Applications: The findings confirmed that it can be applied in both manufacturing and services business. Due to the lower resource investment, it can be implemented in any company like small, medium, and large company.