scholarly journals Integration of value stream map and strategic layout planning into DMAIC approach to improve carpeting process

2017 ◽  
Vol 10 (1) ◽  
pp. 74 ◽  
Author(s):  
Ayman Nagi ◽  
Safwan Altarazi
Keyword(s):  
Six Sigma ◽  
Control Charts ◽  
Process Capability ◽  
Poor Quality ◽  
Value Stream Mapping ◽  
Effect Analysis ◽  
Pareto Analysis ◽  
Value Stream ◽  
Sigma Level ◽  
Strategic Layout

Purpose: This paper presents an implementation of the Six Sigma DMAIC approach implementing lean tools and facilities layout techniques to reduce the occurrence of different types of nonconformities in the carpeting process. Such carpeting process can be found in several industries such as construction, aviation, and automotive.Design/methodology/approach: The improvement process was built through a sequential implementation of appropriate interconnected tools at each phase of the DMAIC approach. Utilized tools included: Pareto analysis, control charts, Ishikawa chart, 5-whys, failure mode and effect analysis, process capability ratio, value stream mapping, and strategic layout planning.Findings: The carpeting process capability, quality of the product, customer satisfaction, and cost of poor quality were significantly improved. Explicitly, the sigma level was improved from 2.297 to 2.886 and the defects per million opportunities (DPMO) was reduced from 21615 to 3905.Originality/value: This paper has approved the capability of the Six Sigma DMAIC approach to analyze, investigate, and remove the root causes of the carpeting (preparation-installation) process nonconformities .

scholarly journals APLIKASI LEAN SIX-SIGMA UNTUK MENGURANGI PEMBOROSAN DI BAGIAN PACKAGING SEMEN

2020 ◽  
Vol 7 (2) ◽  
pp. 143
Author(s):  
Reni Dwi Astuti ◽  
Lathifurahman Lathifurahman
Keyword(s):  
Failure Mode ◽  
Six Sigma ◽  
Lean Manufacturing ◽  
Fish Bone ◽  
Lean Six Sigma ◽  
Value Stream Mapping ◽  
Effect Analysis ◽  
Value Stream ◽  
Transportation Motion

Hasil observasi di PT. Holcim Indonesia Tbk, pabrik Cilacap, didapati banyaknya pemborosan di bagian pengepakan semen, termasuk banyaknya produk cacat kemasan, sehingga banyak semen tercecer dan harus mengulangi proses pengepakan. Penelitian ini dilakukan untuk mengidentifikasi pemborosan selama proses pengepakan menggunakan  pendekatan lean manufacturing dengan value stream mapping. Sementara tingkat kualitas dianalisis dengan metode six-sigma. Penyebab kecacatan produk dianalisis dengan fish-bone diagram. Failure Mode and Effect Analysis (FMEA) digunakan untuk merancang ususlan perbaikan. Pemborosan yang teridentifikasi meliputi : transportation, motion, waiting, over processing, dan defect. Usulan perbaikan untuk mengurangi pemborosan yaitu dengan penggabungan stasiun penimbangan dan stasiun pemeriksaan, sehingga memberikan estimasi peningkatan  process cycle effisiensi  dari 39,1% menjadi 46,69. Sedangkan upaya untuk mengurangi cacat produk dilakukan dengan perawatan preventif mesin packer.

scholarly journals Six Sigma as a method of improving the quality of service process

2018 ◽  
Vol 19 (19) ◽  
pp. 10-15 ◽  
Author(s):  
Kamila Kowalik
Keyword(s):  
Six Sigma ◽  
Service Process ◽  
Value Stream Mapping ◽  
Pareto Chart ◽  
Value Stream ◽  
Sigma Level ◽  
Fishbone Diagram ◽  
Mapping Process ◽  
The Impact

Abstract The objective of the analysis conducted and described in this paper has been to present the practical application of the Six Sigma method based on the DMAIC cycle in improving the quality of the service process. The first part of the article contains the theoretical framework of six sigma and the issue of using its tools in the aspect of services. Afterwards, there has been calculated the initial sigma value which indicated the need for improvement. Measurement phase has been developed by the value stream mapping, process FMEA and customer survey which results have been analyzed in Pareto chart and fishbone diagram. Improve phase includes the Impact&Effort Matrix and target sigma level that can be achieved as a result of failures reducing and service quality improvement.

scholarly journals PERBAIKAN KUALITAS PROSES PRODUKSI DENGAN PENDEKATAN LEAN-SIGMA DI PT. AUTOKORINDO PRATAMA, GRESIK

Jurnal IPTEK ◽  
2016 ◽  
Vol 20 (2) ◽  
pp. 1
Author(s):  
Ni Luh Putu Hariastuti ◽  
Rony Nur Cahya
Keyword(s):  
Failure Mode ◽  
Six Sigma ◽  
Value Stream Mapping ◽  
Effect Analysis ◽  
Pareto Chart ◽  
Value Stream ◽  
Fishbone Diagram

<p class="Default">PT. Autokorindo Pratama Gresik adalah sebagai salah satu produsen <em>velg</em> <em>truck</em> dan <em>bus</em> di Indonesia. Penelitian ini menitiberatkan pada penggabungan konsep<em> lean manufactur</em> dan konsep <em>six sigma </em> yaitu <em>lean sigma</em> untuk memperbaiki kualitas. <em>Tools lean sigma </em>yang dipakai pada penelitian ini adalah <em>Value Stream Mapping</em>, <em>pareto chart</em>, <em>fishbone </em>diagram, dan Failure Mode and Effect Analysis. Dari hasil penelitian diperoleh <em>waste</em> terkritis yaitu <em>waste</em> <em>defect</em>, <em>waste motion</em>, dan <em>transportation</em> dan <em>waste waiting </em>pada proses produksi <em>disc</em>, <em>rim</em>, <em>ring, assy,</em> dan <em>paint</em>. Dalam penelitian ini jenis <em>waste</em> <em>defect</em> tertinggi adalah dimensi <em>part</em> tidak sesuai pada proses <em>expanding </em>yang terdapat pada<em> </em>proses produksi <em>rim</em> dengan jumlah <em>defect</em> 1900 unit. Dan <em>waste transportation</em> adalah jarak antara proses <em>assy</em> dengan proses paint sejauh 100 m. Dengan perbaikan ini diharapkan dapat menyelesaikan masalah yang berkaitan dengan meminimalisasi terjadinya <em>waste</em> <em>defect</em>, <em>waiting</em>, <em>motion</em>, dan <em>transportation</em>. </p><p><strong> </strong></p><p><strong>Kata Kunci  : </strong><em>Waste, Lean Sigma,Value Stream Mapping, Pareto Chart, Fishbone Diagram, </em>dan <em>Failure Mode and Effect Analysis. </em></p>

scholarly journals LEAN SIX SIGMA: MULTIPLE CASE STUDY

2018 ◽  
Vol 9 (1) ◽  
pp. 74
Author(s):  
Orlando Roque Da Silva ◽  
Alessandro Marco Rosini ◽  
Arnoldo J H Guevara ◽  
Angelo Palmisano ◽  
Delvio Venanzi
Keyword(s):  
Six Sigma ◽  
Lean Manufacturing ◽  
Lean Six Sigma ◽  
Value Stream Mapping ◽  
Exploratory Research ◽  
Value Stream ◽  
Multiple Case ◽  
Mapping Techniques ◽  
And Control

Lean Six Sigma is a management focused on quality and productive performance in operating systems. This article discusses the foundations of this methodology through of two different conceptions of management, Lean Manufacturing and Six Sigma. First of the article explain the DMAIC (define measure, analyze, improve and control) and their respective phases, after the Lean philosophy with the sipoc and value stream mapping techniques. The article aims to show integration of these two conception and their results. The methodology consisted in a theory was based on a literature search an exploratory research which consisted of three case studies in differences companies located in Sorocaba, São Paulo. In this article studies the applying of Lean Six Sigma and its results.

Package Chip Defect Reduction on Integrated Circuit

2013 ◽  
Vol 462-463 ◽  
pp. 578-584
Author(s):  
Kulpiya Seri ◽  
Senjuntichai Angsumalin
Keyword(s):  
Integrated Circuit ◽  
Six Sigma ◽  
Control Charts ◽  
Water Pressure ◽  
Process Capability ◽  
Optimal Setting ◽  
The One ◽  
Five Phases ◽  
And Control ◽  
Six Sigma Approach

This research applies Six Sigma approach in order to reduce defect by increasing the assembly process capability index (Cpk) of Integrated Circuit (IC) production process. This study applies five phases (DMAIC) of Six Sigma approach beginning with define (D), measure (M), analyze (A), improve (I) and control (C) phases, respectively. The response of the research identified in the define phase is the chipped width with Cpk of 0.66 determined from the measure phase. The half-factorial experiments are implemented in the analyze phase to find the significant factors which are water temperature, water pressure and feed rate. In improve phase, the additioanl expriments are performed according to the Box-Behnken design in order to determine the non-linear relation between the chipped width and all mentioned factors. The optimal setting of each factors are determined by applied the response surface optimizer. Under the optimal setting, the control charts are used in the control phase to monitor the chipped width. The resulted Cpk of the response is increased to 1.39 which is greater than the one-sided accpetable process capability of 1.25.

scholarly journals Usulan Pengendalian Kualitas Produksi Benang Carded dengan Metode Six Sigma

2018 ◽  
Vol 4 (1) ◽  
pp. 38
Author(s):  
Abdul Manan ◽  
Firdanis Setyaning Handika ◽  
Ahmad Nalhadi
Keyword(s):  
Production Process ◽  
Failure Mode ◽  
Six Sigma ◽  
Risk Priority Number ◽  
Effect Analysis ◽  
Sigma Level ◽  
Mode Effect ◽  
Target Set ◽  
Failure Mode Effect Analysis

A yarn company strives to produce good and quality products, but the production process that is carried out by each person will produce products targeted at a target that has been set at 5%. This study uses the Six Sigma method but only until the improvement stage. The research is to determine the DPMO value and sigma level in the spinning production process, to know what factors cause defects and new parameters to reduce the defect. Based on the results of the study that the DPMO on the type of CD thread in the spinning section is 17,130 and the sigma level is 3,6. The level of sigma that has dominated the Indonesian industry average, but has a defect of 8.7%, the target set at 5%. Damaged and dirty apron, clogged trumpet, and leaky hose are factors that plan defects. Furthermore, with Failure Mode Effect Analysis (FMEA), the highest value of Risk Priority Number (RPN) in tangled defects is that the apron is damaged (140) and clogged trumpet (120), while the highest RPN value is gross dirty, i.e., dirty apron (150) and hose leaking lubricant (120).

scholarly journals IMPLEMENTASI METODE LEAN SIX SIGMA PADA PRODUKSI WAJAN NOMOR 18 DI CV. XYZ

2019 ◽  
Vol 8 (2) ◽  
Author(s):  
Siti Hardianti, Neva Satyahadewi, Nurfitri Imro’ah
Keyword(s):  
Failure Mode ◽  
Six Sigma ◽  
Lean Six Sigma ◽  
Value Stream Mapping ◽  
Risk Priority Number ◽  
Value Stream

Pengendalian kualitas dapat dilakukan dengan berbagai cara, diantaranya menggunakan metode Lean Six Sigma. Metode Lean Six Sigma dapat menunjukkan jalannya proses produksi sehingga diketahui pemborosan, kecacatan dan proses terjadinya produksi melalui value stream mapping. Lean Six Sigma dapat diterapkan di bidang industri, satu diantaranya adalah perusahaan CV. XYZ. Perusahaan tersebut memproduksi wajan dengan nomor 10, 11, 12, 13, 14, 15, 16, 18, 20, 22, 24, 26, 28 dan 30. Wajan nomor 18 adalah wajan yang paling diminati konsumen. Tahapan dalam Lean Six Sigma dimulai dari define, measure dan analyze. Jenis kecacatan diklasifikasikan menjadi empat kelas yaitu sangat serius (A), serius (B), cukup serius (C) dan tidak serius (D) dengan jumlah observasi sebanyak 78 hari. Kecacatan terbesar terjadi di kelas cacat sangat serius yaitu sebesar 44,38%. Level sigma merupakan kemungkinan besar kecacatan yang akan terjadi jika memproduksi satu juta produk. Pada penelitian ini, level sigma yang dihasilkan kecacatan sangat serius adalah 3,2, sehingga dengan menggunakan nilai Defect Per Million Oppertunities (DPMO) dapat disimpulkan bahwa dalam satu juta produksi kemungkinan produk cacat sebesar 44.211 buah. Berdasarkan analisis Failure Mode and Effect Analyze (FMEA), diketahui penyebab kecacatan sangat serius dikarenakan material dengan nilai Risk Priority Number (RPN) sebesar 84. Sehingga dengan menggunakan kriteria penilaian RPN diketahui bahwa kecacatan yang disebabkan oleh material tergolong sedang.  Kata Kunci: Demerit, Failure Mode and Effect Analyze. 

scholarly journals Six Sigma Implementation Efficiency in an Automobile Firm

2019 ◽  
Vol 8 (4) ◽  
pp. 12125-12129
Keyword(s):  
Six Sigma ◽  
Continuous Process ◽  
Quality Level ◽  
Manufacturing Strategy ◽  
New Paradigm ◽  
Research Activity ◽  
Productivity Improvement ◽  
Effect Analysis ◽  
Pareto Analysis ◽  
Study Results

Six Sigma a new paradigm and fast growing manufacturing strategy executed and streamlined across recent automobile firms. This methodology have been faster pace of growth worldwide which helps to enhance productivity and quality improvement on existing process robust to monitor quality variations across manufacturing firms. To respond to quality changes happening every firm within the industry aligning themselves to show continuous process changes by building their existing infrastructure through Kaizen, JIT manufacturing, Business Process Reengineering practices to attain global competitive advantage and also to meet changing global customer demands by providing high quality products. This study results discussed six sigma implementation practices and various defects analysis methods followed in an automobile firm for quality and productivity improvement. This study used systematic literature review approach by analyzing existing major defective parts from the overall manufacturing products of the firm and has been analyzed using quality tools like Pareto analysis, Cause and Effect Analysis, 5 - Why analysis and Scatter diagram. The findings from this study definitely allow future researchers to progress their research activity in this field of activity helps them to open up new opportunities on six implementation issues to develop and evolve. Overall this study concluded with the suggestion of implementing Six Sigma DMAIC (Define–Measure-Analyze-Improve-Control) methodology which provides a framework to identify, quantify and eliminate sources of variation by optimizing operation variables which helps the firm to improve and sustain performance. The motive of this study is to achieve higher quality level for mutual benefits of organization and customer

scholarly journals VALUE STREAM MAPPING OF OCEAN IMPORT CONTAINERS: A PROCESS CYCLE EFFICIENCY PERSPECTIVE

2021 ◽  
Vol 8 (4) ◽  
pp. 393-405
Author(s):  
Mohan Saini ◽  
Anastasia Efimova ◽  
Felicita Chromjaková
Keyword(s):  
Six Sigma ◽  
Lean Six Sigma ◽  
Value Stream Mapping ◽  
Container Transportation ◽  
Expert Review ◽  
Value Stream ◽  
Import Containers ◽  
Process Perspective ◽  
Import Container ◽  
Cycle Efficiency

International cargo transportation is majorly dependent on marine transport, which moves 80% of the international cargo. With the increase in vessel size and the same yard area available for container transportation, it is important to study the processes and understand the efficiency of the container operations process. This research paper aims to review the import container transportation process and understand the process cycle efficiency through lean six sigma concepts. The process is evaluated from the operations process perspective and documentation process at one of the ports of India. The research has been designed by conducting an industry expert review on the process of container transportation from vessel berthing to gate out for import containers, utilising lean six sigma principles such as value stream mapping (VSM) and process cycle efficiency. The results have contributed to the existing knowledge in identifying the waste in the container handling process and demonstrated the inefficiency in the system from the perspective of waiting time of containers due to customs examination, scanning, and inter-terminal handling and movement. The process cycle efficiency of 40% is calculated by analysing the detailed time of handling containers from vessel berthing to gate out. A new future value stream mapping is proposed considering the process cycle efficiency. Future studies will focus on studying this process for export containers and benchmarking the results with the top-performing ocean ports globally.

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