Title: Lean Six Sigma implementation in an Indian manufacturing organisation: a case study

Authors: Yogesh Mishra; Milind Kumar Sharma; Vinod Yadav; M.L. Meena; G.S. Dangayach

Addresses: Department of Mechanical Engineering, Malaviya National Institute of Technology Jaipur, Jaipur, 302017 Rajasthan, India ' Department of Production and Industrial Engineering, Faculty of Engineering and Architecture, Jai Narain Vyas University Jodhpur, Rajasthan State, India ' Department of Automobile Engineering, Manipal University Jaipur, Jaipur, 303007, Rajasthan, India ' Department of Mechanical Engineering, Malaviya National Institute of Technology Jaipur, Jaipur, 302017, Rajasthan, India ' Department of Mechanical Engineering, Malaviya National Institute of Technology Jaipur, Jaipur, 302017, Rajasthan, India

Abstract: Lean Six Sigma (LSS) is a blend of the variability reduction tools from Six Sigma and the non-value added activities elimination tools from lean manufacturing. It succeeds to generate the bottom-line savings to the organisation. Through the application of a case study method, the study presents an implementation of design, measure, analyse, improve, and control (DMAIC) and the benefits of the hybrid LSS approach. The LSS framework is applied to the Indian automotive industry and presented in this paper. There were a lot of improvements found in the key metrics, productivity level, and overall equipment effectiveness when the proposed framework is implemented. The LSS approach is applied to a real-world problem and it gets an overall increased level of 95.16% in concern of productivity, reduction of change over time from six minutes to two minutes per setup change, and wrong fitting assembly cases reduce to zero. This study helps the practitioners in understanding and step by step implementation of the LSS approach.

Keywords: Lean Six Sigma; LSS; lean manufacturing; Six Sigma; DMAIC; productivity improvement.

DOI: 10.1504/IJSSCA.2021.120228

International Journal of Six Sigma and Competitive Advantage, 2021 Vol.13 No.1/2/3, pp.76 - 100

Received: 06 May 2020
Accepted: 07 Dec 2020
Published online: 11 Jan 2022 *

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