Improvement Productivity and Quality by Using Lean Six Sigma: A Case Study in Mechanical Manufacturing

Abstract

Intelligent integrated production systems are always of interest to production planners. However, in order to deploy and improve from a mere processing factory to a processing factory with an integrated intelligent production system, it requires a team of employees, engineers, and managers to always have a spirit of innovation, continuously improving existing semi-automatic equipment into automatic ones, aiming to move towards a smart factory. The result of this research is to reduce waste in the process of assembling mechanical products by applying the DMAIC process (Define, Measure, Analysis, Improve, Control), lean six sigma tools, the test of variance, hypothesis testing and experimental design. IBM SPSS 2020, Matlab2019a, and Minitab 18 software are used for data analysis and Solid work software is used to design and simulate mechanical parts. This study shows a systematic approach to analysis to find the root cause of defects in the product assembly process, a method of diagnosing defective products as well as the application of charts to the analysis of waste products, and improving quality by applying basic quality management tools such as Pareto charts, fishbone diagrams, value stream mapping, man-machine chart, and failure tree analysis (FTA). Clearly identify the types of waste such as components sliding on top of each other without rust, and surface roughness of metal products that do not meet the standards. Experimental design models and statistical models, and statistical tests are applied to Lean six sigma’s DMAIC model in the process of analyzing the machining process. The results of analysis and process improvement have improved in a reduction of scrap in the assembly line of mechanical products by 59.66% per year, an increase in assembly-line productivity by 7.8% per year, and a decrease in waste costs incurred by 59.66% per year. The application of the DMAIC cycle to improve the quality of the assembly line of mechanical products, in addition to reducing waste, also reduces the quality cost of the assembly line.