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Lean Six Sigma Application in Manufacturing

Author: ShiPeiJun
Tutor: ZhaoXia；ShenYiBing
School: Shanghai Jiaotong University
Course: Control Engineering
Keywords: Lean Six Sigma DMAIC Lighting Measurement System Improvement
CLC: TM923.07
Type: Master's thesis
Year: 2011
Downloads: 111
Quote: 0
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Abstract


Lean and Six Sigma is the world’s most advanced quality management concepts, Application of lean and Six Sigma enable enterprises to improve product quality, reduce costs and even change the corporate culture to keep continuous vitality. Which is a powerful weapon of constantly enhance enterprises’operational performance. This article first describes the two management methods, and then combines the advantages of both methods of Lean Six Sigma methods, and finally the project practice.Lean production methods produced product variety as much as possible to meet customer requirements, and through use of all methods and means to eliminate all the waste (human, material, time and space) to meet customer requests for price. Lean production requires elimination of all waste, the pursuit of excellence and continuous improvement in production processes. Remove all non-value added jobs; streamline product development and design, production, management does not produce added value in all work.Six Sigma is a pursuit of customer-oriented philosophy: continuous improvement and reflects the learning-based corporate culture. Six Sigma focus on the root causes of defects, put the resources into understanding, improvement and control of reasons rather than on quality inspection, service and other activities. Six Sigma has a set of rigorous tools and methods to help companies promote the implementation of process optimization work, to identify and exclude cost of waste. Lean Six Sigma is a combination of Lean and Six Sigma, its nature is to eliminate waste. Lean Six Sigma’s aim is to integrate Lean and Six Sigma management to absorb the advantages of two production models, to make up for lack of a single mode of production to achieve better management results.Finally, I applied the Lean Six Sigma into my job. By using the DMAIC approach to run a project—Lighting Measurement System Improvement. The project concerns about the high misjudgment failure rate, which reaching 70 percent, seriously affecting the efficiency of production, an increase of personnel, equipment and material waste. Set up a project group, the first in the definition (D) and measurement (M) phase, understood production problems in a comprehensive way, and evaluated the existing lighting measurement system status. The project target is to reduce the misjudgment failure rate to 10%. In the analysis (A) phase, through the application of Lean Six Sigma tools to analyze in detail all aspects of the production data in two steps to find the main reasons, first find the problem in the driver, then depth of driver research. In the improvement (I) phase, two improvement proposals were raised: change driver type or try to use the system of compensation. Lean thinking and ultimately from the economic point of view, chose to use the power compensation system, making the misjudgment failure rate reduced to less than 1%, which obtain satisfactory results than expected. In the control (C) phase, production management tools help to improve long-term results. And the improvement concept was rolling to other products, reducing production costs. Hope the project’s successful implementation of the application of Lean Six Sigma can have some significance.

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CLC: > Industrial Technology > Electrotechnical > Electrification,electrical energy application > Electrical lighting > General issues > Light testing,repair methods and equipment
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