Title: Lean Six Sigma improvement: the case of a supplement manufacturer

Authors: Wesley S. Boyce; Megan O'Brien; Stephen Meidinger; Emerson Cole

Addresses: University of Nebraska – Lincoln, 1400 R Street, Lincoln, NE 68588, USA ' University of Nebraska – Lincoln, 1400 R Street, Lincoln, NE 68588, USA ' University of Nebraska – Lincoln, 1400 R Street, Lincoln, NE 68588, USA ' University of Nebraska – Lincoln, 1400 R Street, Lincoln, NE 68588, USA

Abstract: This case study presents the application of Lean Six Sigma (LSS) methodology to improve the production process of a firm that produces a home health product in the USA. The goal is to demonstrate how this process is improved using LSS methods. Define, measure, analyse, improve and control (DMAIC) is used to improve the production process in a structured manner. This includes using VSM to create a current state outline of the process and to identify needed areas of improvement, as well as utilising the five whys approach to identify the root cause of problems. It is found that applying LSS methodology led to positive results, such as improved on-time deliveries, reduced idle times, and raw materials reductions. The techniques used in this work can aid practitioners that want to learn more about making improvements at their own firms using LSS methods.

Keywords: waste reduction; performance improvement; DMAIC; value stream mapping; Lean Six Sigma; quality.

DOI: 10.1504/IJPQM.2025.148466

International Journal of Productivity and Quality Management, 2025 Vol.46 No.1, pp.41 - 56

Received: 23 Jun 2023
Accepted: 19 Jul 2023
Published online: 08 Sep 2025 *

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