Title: Productivity improvement using DMAIC in a Caravan Manufacturing company

Authors: Sharfuddin Ahmed Khan; M. Affan Badar; Mohammed Alzaabi

Addresses: Industrial Engineering and Engineering Management Department, University of Sharjah, Sharjah, 27272, United Arab Emirates ' Applied Engineering and Technology Management Department, Indiana State University, Terre Haute, IN 47809, USA ' Dubai Corporation for Ambulance Services, Dubai, United Arab Emirates

Abstract: This paper deals with productivity enhancement of a Caravan Manufacturing company located in United Arab Emirates. A continuous improvement technique: define, measure, analyse, improve, and control (DMAIC) has been implemented in the production department of the case company. A model was developed using Arena software to simulate the caravan manufacturing process and the proposed solution. The model was verified and validated. Control charts were also developed to control and maintain productivity in the case company. It was suggested to change caravan doors from wooden to aluminium. After thorough and careful analysis using simulation, it was found that the production of caravan increased from six per every three days to 11 per every three days. This resulted in increased profit of 500 AED (USD 135) per caravan, 600 more caravans per year and enhanced product life cycle. Moreover it resulted in saving cost, increased production, and product life cycle.

Keywords: productivity improvement; DMAIC; define, measure, analyse, improve, and control; caravan manufacturing; Pareto chart; cause and effect diagram; simulation; control charts.

DOI: 10.1504/IJPQM.2020.107825

International Journal of Productivity and Quality Management, 2020 Vol.30 No.2, pp.234 - 251

Received: 20 Nov 2018
Accepted: 05 Feb 2019
Published online: 22 Jun 2020 *

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