You are here

Home ยป Content

Integration of Value Stream Map and Strategic Layout Planning into DMAIC Approach to Improve Carpeting Process

Journal Name:

  • Journal of Industrial Engineering and Management

Publication Year:

  • 2017
DOI: 
https://doi.org/10.3926/jiem.2040

Key Words:

Author NameUniversity of Author
Abstract (2. Language): 
Purpose: This paper presents an implementation of the Six Sigma DMAIC approach implementing lean tools and facilities layout techniques to reduce the occurrence of different types of nonconformities in the carpeting process. Such carpeting process can be found in several industries including construction, aviation, and automotive. Design/methodology/approach: The improvement process was built through a sequential implementation of appropriate interconnected tools at each phase of the DMAIC approach. Utilized tools included: Pareto analysis, control charts, Ishikawa chart, 5-Whys, failure mode and effect analysis, process capability ratio, value stream map, and strategic layout planning. Findings: The carpeting process capability, quality of the product, customer satisfaction, and cost of poor quality were significantly improved. Explicitly, the sigma level was improved from 2.297 to 2.886 and the defects per million opportunities was reduced from 21615 to 3905. Originality/value: This paper has demonstrated the coherent implementation of several quality tools, value stream map, and systematic layout planning within the DMAIC approach.
Bookmark/Search this post with
FULL TEXT (PDF): 
PDF icon arastirmax-integration-value-stream-map-and-strategic-layout-planning-dmaic-approach-improve-carpeting-process.pdf
  • 1
74
97
  • English

REFERENCES

References: 

Akbulut-Bailey, A.Y., Motwani, J., & Smedley, E.M. (2012). When Lean and Six Sigma converge: a case
study of a successful implementation of Lean Six Sigma at an aerospace company. International Journal of
Technology Management, 57(1/2/3), 18-32.
Anderson, N.C., & Kovach, J.V. (2014). Reducing welding defects in turnaround projects: A lean six sigma
case study. Quality Engineering, 26(2), 168-181. https://doi.org/10.1080/08982112.2013.801492
Antony, J., Antony, F.J., Kumar, M., & Cho, B.R. (2007). Six sigma in service organizations: Benefits,
challenges and difficulties, common myths, empirical observations and success factors. International
Journal of Quality & Reliability Management, 24(3), 294-311. https://doi.org/10.1108/02656710710730889
Box, G.E., & Cox, D.R. (1964). An analysis of transformations. Journal of the Royal Statistical Society, Series
B (Methodological), 211-252.
Chen, M., & Lyu, J. (2009). A Lean Six-Sigma approach to touch panel quality improvement. Production
Planning and Control, 20(5), 445-454. https://doi.org/10.1080/09537280902946343
Cheng, C.Y., & Chang, P.Y. (2012). Implementation of the lean six sigma framework in non-profit
organizations: A case study. Total Quality Management & Business Excellence, 23(3/4), 431-447.
https://doi.org/10.1080/14783363.2012.663880Christopher, M., & Rutherford, C. (2004). Creating supply chain resilience through agile Six Sigma. Critical
Eye, 7(1), 24-28.
Delgado, C., Ferreira, M., & Branco, M.C. (2010). The implementation of lean Six Sigma in financial
services organizations. Journal of Manufacturing Technology Management, 21(4), 512-523.
https://doi.org/10.1108/17410381011046616
Desai, D., & Patel, M. (2009). Impact of Six Sigma in a developing economy: analysis on benefits drawn
by Indian industries. Journal of Industrial Engineering and Management, 2(3), 517-538.
https://doi.org/10.3926/jiem.2009.v2n3.p517-538
Franchetti, M. (2014). Continuous improvement and facility redesign through the lean DMAIC Six Sigma
approach: a final assembly work unit case study from Ohio, USA. International Journal of Six Sigma and
Competitive Advantage, 8(2), 83-94. https://doi.org/10.1504/IJSSCA.2014.064253
Furterer, S., & Elshennawy, A.K. (2005). Implementation of TQM and lean Six Sigma tools in local
government: a framework and a case study. Total Quality Management & Business Excellence, 16(10),
1179-1191. https://doi.org/10.1080/14783360500236379
Jacobsen, J. (2011). Ford Team Project Builds Relationships, Improve Quality. http://krytonmetals.com/wpcontent/
uploads/ford-team-project-builds-relationships.pdf (Accessed: July 2016).
Krueger, D.C., Mellat-Parast, M., & Adams, S. (2014). Six Sigma implementation: a qualitative case study
using grounded theory. Production Planning and Control, 25(10), 873-889.
https://doi.org/10.1080/09537287.2013.771414
Kumar, S., & Sosnoski, M. (2009). Using six sigma DMAIC to systematically improve shopfloor
production quality and costs. International Journal of Productivity and Performance Management, 58(3), 254-273.
https://doi.org/10.1108/17410400910938850
Li, M.H., Al-Refaie, A., & Yang, C.Y. (2008). DMAIC approach to improve the capability of SMT solder
printing process. IEEE Transactions on Electronics Packaging Manufacturing, 31(2), 126-133.
https://doi.org/10.1109/TEPM.2008.919342
Lucas, J.M., & Saccucci, M.S. (1990). Exponentially weighted moving average control schemes: properties
and enhancements. Technometrics, 32(1), 1-12. https://doi.org/10.1080/00401706.1990.10484583
Mandahawi, N., & Obeidat, S.M. (2012). Six sigma implementation to minimise weight variation for Baby
Lido Diaper manufacturing company. International Journal of Six Sigma and Competitive Advantage, 7(2/3/4),
243-255. https://doi.org/10.1504/IJSSCA.2012.053472Montgomery, D.C. (2009). Introduction to statistical quality control (6th ed.). New York: Wiley.
Neuman, R.P., & Cavanagh, R. (2000). The six sigma way: How GE, Motorola, and other top companies are honing
their performance. New York: McGraw-Hill.
Tompkins, J.A. (2010). Facilities planning (4th ed.). New York: Wiley.
Osborne, J.W. (2010). Improving your data transformations: Applying the Box-Cox transformation.
Practical Assessment, Research and Evaluation, 15(12), 1-9.
Srinivasan, K., Muthu, S., Devadasan, S.R., & Sugumaran, C. (2016a). Enhancement of sigma level in the
manufacturing of furnace nozzle through DMAIC approach of Six Sigma: a case study. Production
Planning and Control, 27(10), 810-822. https://doi.org/10.1080/09537287.2016.1143130
Srinivasan, K., Muthu, S., Devadasan, S.R., & Sugumaran, C. (2016b). Six Sigma through DMAIC phases:
a literature review. International Journal of Productivity and Quality Management, 17(2), 236-257.
https://doi.org/10.1504/IJPQM.2016.074462
Tong, J.P.C., Tsung, F., & Yen, B.P.C. (2004). A DMAIC approach to printed circuit board quality
improvement. The International Journal of Advanced Manufacturing Technology, 23(7/8), 523-531.
https://doi.org/10.1007/s00170-003-1721-z
Vinodh, S., Kumar, S. V., & Vimal, K.E.K. (2014). Implementing lean sigma in an Indian rotary switches
manufacturing organisation. Production Planning & Control, 25(4), 288-302.
https://doi.org/10.1080/09537287.2012.684726
Yang, H.M., Choi, B.S., Park, H.J., Suh, M.S., & Chae, B.K. (2007). Supply chain management Six Sigma:
A management innovation methodology at the Samsung Group. Supply Chain Management: An
International Journal, 12(2), 88-95. https://doi.org/10.1108/13598540710737271

Thank you for copying data from http://www.arastirmax.com