Operational Excellence for Improving Manufacturing Performance Using Lean Six Sigma
Volume 8, Issue 1 Attia Hussien Gomaa
Published online:8 July 2023
Article Views:20
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Operational excellence is the process of aligning people, resources, processes and capabilities to achieve sustainable growth and continuous improvement. Reducing costs and improving customer satisfaction is a top priority for every organization. Lean Six Sigma (LSS) is a continuous improvement strategy that increasing process performance resulting in reducing costs and enhancing customer satisfaction. The purpose of thisstudy is to investigate the status of LSS implementation in manufacturing domain. An integrated LSS-DMAIC framework is developed for improving process performance. In this context, the proposed framework was applied in a car spare parts manufacturer in Egypt. The main factors causing process defects and wastes were identified, and the solutions applied led to an increase in quality rate and value-added-time. During three months, product quality rate (first time) increased from 26.7% to 80.0%, and quality rate (after rework) increased from 80.0% to 100%, resulting in sigma level (first time) increasing from 2.12 to 2.34, and sigma level (after rework) from 2.34 to 6.0. Furthermore, processing lead time was reduced from 1,847 to 915 sec./unit, which led to improved value-added process efficiency from 47% to 79%.
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Gomaa, A.H. (2023). Operational Excellence for Improving Manufacturing Performance Using Lean Six Sigma. International Journal of Business and Administrative Studies, 9(2), 1-19. https://dx.doi.org/10.20469/ijbas.9.10001-2
