ABSTRACT
This case study presents how Lean manufacturing techniques such as onepiece flow, kanban, and U-shaped cells were used to achieve Six Sigma through continuous improvement efforts and reducing non-value-adding processes in a case study. The objective of the project implementation was to improve quality to a Six Sigma level by using the Define-Measure-AnalyzeImprove-Control (DMAIC) methodology and implementing Lean manufacturing techniques. Six Sigma is a continuous improvement technique with a goal of 3.4 defects per million. In this case study, Six Sigma tools are applied to a process that is incurring an unacceptable level of defects and not meeting
CONTENTS
Executive Summary ............................................................................................ 213 Introduction ......................................................................................................... 214 Define .................................................................................................................... 215 Measure ................................................................................................................ 217 Analyze ................................................................................................................. 220
Analyze Production and Quality Requirements ....................................... 221 Evaluate Material Handling Requirements ................................................ 221
Improve ................................................................................................................ 221 Total Employee Involvement ........................................................................222 Kanban Control System .................................................................................222 Elimination of Defects ...................................................................................222 Individual Responsibility/Immediate Feedback .......................................222 Flexibility/Delivery to the Point of Use ......................................................223 Setup Time Reduction ....................................................................................223
