Improve Productivity and Quality Using Lean Six Sigma: A Case Study

Abstract

Continuous improvement activities are widely deployed, applying the DMAIC cycle in the Lean Six Sigma method combined with 5s activities and industrial engineering tools such as Man-Machine chart statistics tools in DFSS (Design For Six Sigma). The results of the improvement activity must be approved and operated by the machine operator, measuring the loyalty of operators, users and system maintainers after kaizen against satisfaction criteria, technicality, usefulness and convenience are needed. This study proposes a model that combines the PLS - SEM method to measure user loyalty and implement a training program for users on incorrect performance results to improve CDIO standards. The result is a reduction of workers at the processing line from 4 people on two shifts to 2 people, and the amount of money brought in is 10,224 USD per year. Defect of negative outside diameter decreased from 31.2% to 4.5% based on the amount of waste reduction of USD 980 per year. In terms of productivity increased from 15 units per hour per person to 30 units.