Integration of Lean Manufacturing And Six Sigma Using Statistical Methods
Journal Title: IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) - Year 2018, Vol 15, Issue 4
Abstract
This research integration of lean manufacturing and six-sigma was carried out in the Nigerian Breweries Enugu Plant where management strategies were not so developed. The main objective of this work was focused on the minimization of the line wastes such as time, over-processing, over-production or defects. The DMAIC (Define-Measure-Analyse-Improve-Control) was the methodology used for the identification of compatible lean techniques and strategies for the reduction of defects and rejects bottles in the company. Data were collected and analyzed using statistical methods. The result showed the production line A rejects 0.37% of the produced bottles against 0.23% of the production line B. This showed that production line A rejects one bottle in every 271 bottles against one bottle from 435 bottles in the production line B. The result also showed that minimum and maximum value for extraction force were 20 and 40kg. Though the great time was in the inventory before the washing machines, 37.7% reduction in value added time was achieved through elimination of buffers. The problem of line A was placed on the Filling-Capsule machine which put a crown type cap and works without cork. However, the 2 defects on the Labelling (Line A) where found at the beginning of the batch production and it was the moment that appears more problems to set the new label bovines of the new product. The actual situation of the bottling line was represented where the main flow material were the bottles of beverage, though other raw materials were also necessary for the line to produce the final bottle, the bottles flow involves the quantity of other raw materials necessary because each bottle needs one cap, two labels, a box for either 12 or 24 bottles. Thus, the line production suffers some stops and for this reason the uptime available was less than 100%. Only the washing machine was working all time because the configuration and it was the bottleneck with the minimum speed (6450bot/h) and the highest Takt production time (0.558s/bottle). The Lean Six Sigma integration proposed in this work was supported by an extensive literature of most of the techniques involved in both management philosophies. Proper strategies were developed and proposed in this work. Thus, this work had provided solutions for capability and control of processes and other little changes for the company and recommended application of the outcome of this work to other similar sectors.
Authors and Affiliations
Engr. Dr. A. C. Uzorh, Engr. F. Olanrewaju, Engr. I. Nnanna
Keywords
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