Applying Lean Six Sigma for Waste Reduction in a Manufacturing Environment Mohamed K. Hassan The University of Akron Research Foundation, Akron, OH, USA Article Metrics Related Content About the Authors Comments Follow the Authors Abstract 1. Introduction 2. Concepts 3. Waste Reduction as a Quality Improvement Application 4. Prioritization of Alternatives Using Analytic Hierarchy Process 5. Industry Application 6. Conclusions References Abstract This study was applied in a welding wire manufacturing plant to improve the quality of the manufactured welding wires, reducethe manufacturing waste and increase the yield of the manufacturing process, by applying the Lean Six Sigma (LSS) methodology and waste management. LLS is considered one of the successful approaches in the field of quality improvement and cost reduction. The case study plant working environment was analyzed to isolate the root causes for the waste generation. Remedies and countermeasures were suggested and some were implemented. The study compares the performance of the plant before and after implementation of the proposed solutions for waste reduction. Improvements in yield, waste, Defects Per Million Opportunities (DPMO), and sigma levels were achieved.The LSS methodology was linked to the Analytic Hierarchy Process (AHP) to prioritize the causes of waste. The objective was to use an analytical method in judging the influence of the waste causes on the amount of waste to enrich the methodology effectiveness and facilitate some ease of use in the practical field. At a glance: Figures Figure 1
Figure 2 Figure 3 Figure 4 View all figures 12 PrevNext Keywords: Lean Six Sigma (LSS), Analytic Hierarchy Process (AHP), quality improvement, waste management, welding wire American Journal of Industrial Engineering , 2013 1 (2), pp 28-35. DOI: 10.12691/ajie-1-2-4 Received September 10, 2013; Revised October 17, 2013; Accepted October 18, 2013 Copyright © 2013 Science and Education Publishing. All Rights Reserved. Cite this article: MLA Style APA Style Chicago Style Hassan, Mohamed K.. "Applying Lean Six Sigma for Waste Reduction in a Manufacturing Environment." American Journal of Industrial Engineering 1.2 (2013): 28-35. Import into BibTeX Import into EndNote Import into RefMan Import into RefWorks 1. Introduction LeanSix Sigma is a well-known methodology for quality and waste improvement. The Lean Six Sigma methodology is characterized by the DMAIC phases. Motorola Company recognized that there was a pattern of improvement that could naturally be divided into the five phases of problem solving, usually referred to by the acronym DMAIC, which stands for Define-Measure-Analyze-Improve-Control [ 1 ] . DMAIC forms the five major phases of any Six Sigma project. Lean Six Sigma is a disciplined, data-driven methodology used to
eliminate/reduce the process hence the product defects and waste. To achieve Six Sigma qualities, a process must produce no more than 3.4 defects per million opportunities.
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