ABSTRACT
This study applied the dene, measure, analyze, improve, and control (DMAIC) Six Sigma methodology and Lean principles [1] to redesign a nal assembly work unit to increase capacity and reduce costs in a light manufacturing company located in the United States. The nal assembly work unit that was redesigned for this study was responsible for 38% of the company’s revenue stream and experienced various cost and process efciency issues. These issues included an assembly-line imbalance, oating bottleneck operations, safety concerns, high percentages of non-value-added time for employees, housekeeping issues, and storage issues. In addition, the company was seeking to increase production in this work unit to attain a larger market share. To accomplish these goals, the organization applied the Lean Six Sigma approach to create a meaningful and practical road map. This study illustrates such an application including a case study and results. The case study focuses on the creation of value stream maps, line balancing, and facility redesign to identify and track key processes within the facility.
