International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395 -0056
Volume: 04 Issue: 04 | Apr -2017
p-ISSN: 2395-0072
www.irjet.net
Lean Six Sigma Implementation in Textile Industry Rajat Ajmera1, Prabhuling Umarani2 and K.G.Valase3 1,2Dept. 3Professor,
of Mechanical Engineering, Walchand Institute of Technology, Solapur, India
Dept. of Mechanical Engineering, Walchand Institute of Technology, Solapur, India
---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - Lean and Six Sigma are two widely acknowledged
integrated system between Lean Manufacturing and Six Sigma while others would perceive LSS as two different concepts which is adapted in parallel (Assarlind et al. 2012). Moreover, the integration between the two quality management concepts varies between each integration as Assarlind et. al. (2012) points out that each integration may involve transferring of different tools, ideas and philosophies. This leads to many theories on how Lean and Six Sigma could be integrated. Some authors recommended that Six Sigma should lead the initiatives, with Lean tools added during the analysis phase of the initiatives while other authors recommend that Lean should be the backbone of the framework and Six Sigma is used to reduce and then eliminate the variation found. Lean Manufacturing focuses on waste reduction and non-value added activities in production (Womack et al. 1990) while Six Sigma focuses on process variation reduction with both concepts aiming to reduce waste. There is a need towards this integration in quality management as a solution provided via Lean Manufacturing concept would be of no use if the execution of the solution has high variation. The Six Sigma concept on the other hand would give too much focus in reduction of variation only leading to high risk of providing poor service due to long lead times even if the company are operating at Six Sigma level. Even though most would agree that there is a need for the integration of Lean and Six Sigma, most companies would prefer to implement both concepts in isolation (Smith 2003) or in parallel but this would lead to increase of projects and resources while causing conflicts of interest between the two quality management concepts (Bendell 2006). Implementation of both concepts in isolation too will not enable each concept to be adopted effectively as it is constraint by one another’s needs in the organization. Lean and Six Sigma can be compatible whereby both are of quality management (Shah et al. 2008)
business process improvement strategies available to organisations today for achieving dramatic results in cost, quality and time by focusing on process performance. Lean Sigma combines the variability reduction tools and techniques from Six Sigma with the waste and non-value added elimination tools and techniques from Lean Manufacturing, to generate savings to the bottom-line of an organisation. This paper proposes a Lean Sigma framework to reduce the defect occurring in the final product of textile industry. The proposed framework integrates Lean tools within Six Sigma DMAIC methodology to enhance the bottom-line results and win customer loyalty. This paper contributes towards the research upon a structured implementation of LSS in textile industry where it addresses the issues faced by previous works regarding LSS implementation in SMEs
Key Words: Lean six sigma, DMAIC, Productivity, Quality
1. INTRODUCTION Lean Six sigma is a combination of waste elimination and process improvement techniques Lean Manufacturing and Six Sigma. Lean Six Sigma (LSS) concept is the integration of two quality management concepts which are Lean Manufacturing and Six Sigma where by it attempts to increase the scope and size of improvements achieved by either concept alone. Together lean manufacturing and six sigma become more powerful and eliminates the cons of each approach. It applies the tools and techniques of both Lean manufacturing and six sigma. DMAIC are applied with lean environment to achieve bottom line results. Many researchers have been discussing about integrating Lean Manufacturing and Six Sigma to form Lean Six Sigma (LSS) as the latest quality management concept (Hoerl and Gardner 2010;Assarlind et al. 2012). The integration of both models will facilitate the achievement of zero defect manufacturing in organizations complemented by the elimination of nonvalue added activities which leads to greater results than either system can achieve alone (Snee 2010). This paper aims to provide a structured LSS framework which can be adopted in the SME label printing company in order to reduce waste and variation in their production; aiming to increase its productivity while reducing the cost of production.
3. CASE STUDY
2. LEAN SIX SIGMA METHODOLOGY
The developed LSS framework is verified in small scale textile industry. The textile industry produces various types of products like shirt, T-shirt, baba suit, Kurta etc. The management wants to implement LSS because the low productivity and produces high wastage; where it increases the lead time of the production and the cost of the product.
Lean Six Sigma (LSS) concept is the integration of two (2) quality management concepts which are Lean Manufacturing and Six Sigma whereby it attempts to increase the scope and size of improvements achieved by either concept alone. However, different individual and companies view LSS in different ways. Some would perceive LSS as a fully
As quality plays a pivotal role in all aspects of life, reducing the number of defectives, wastes and lead time in textile industry is an important function. Textile industries in India
Š 2017, IRJET
|
Impact Factor value: 5.181
3.1 Lean Six Sigma Framework 3.1.1 Phase 1: Define the problem - Data Collection Define Research Case
|
ISO 9001:2008 Certified Journal
|
Page 1670