Quality and process improvement using lean six-sigma methodology

Abstract

Lean Six Sigma method is recognized widely depend, basically on increasing the benefits without increase in cost and has been implemented predominately in manufacturing industry. This research draws attention to the adoption of Lean Six Sigma in the bullet factory standard (7.62×39)mm, in al shagara industrial complex with a case study. The combination of Lean tools and Six Sigma methodology is used on projects to improve the process by eliminating the variations and creating workflow in a process. Some important tools are used like Pareto chart , failure modes and effect analysis ,fish bone diagram , fault tree analysis and value stream mapping ,according to voice of process and voice of customer, A new modifications in Trimming stage was proposed and practically tested and successfully implemented in the stage . The first modification is adding cover to separate between chips and products the result indicate that the sorting time was reduced from 50min to 15 min. Also the other modification is adding bearing between knife holder and rod , this reduce the defect by 2.5%.