Lean Six Sigma for Productivity Improvements

Abstract

The main goal of the project is the Implementation of lean Six sigma which is a methodology aim to improve the productivity by systematically removing of waste, reduce defects and variation. The methodology is divided into five steps “Define, Measure, Analyze, Improve and Control (DMAIC)”. This case study was carried at engineering company in cutting tools section on specific product “Cone Drill”. The five steps of DMAIC methodology was implemented on the product to reduce the total manufacturing time and reduce the variation which contribute in improving the productivity and decrease the total manufacturing time and cost, also give a less amount of waste. In define phase data have been collected problems and objectives, measured. Data analyzed using MiniTab and Excel and detected the root causes of the problems. By brainstorming best solution carried out. Problems solved and made improvements on total manufacturing time. In control phase improvements monitored and controlled by using check process form. The final results was the total manufacturing time decreased from 130.95 minutes to 70 minutes and this decreased the total cost of the Milling, Lathing, and Sharpening processes cost from 72.6 SDG to 41.3 SDG per unit which this decreased the cost by 43% from previous cost.