Title: Changeover time reduction in TV assembly line using Lean Six Sigma: a case study

Authors: Omayma A. Nada; Mohamed A. El-Dardiry; Zainab E. El-Dardiry

Addresses: Production Engineering and Mechanical Design Department, Faculty of Engineering, Menoufia University, Egypt ' Production Engineering Department, Faculty of Engineering, Alexandria University, Alexandria, Egypt ' Graduate Studies Program, Faculty of Engineering, Menoufia University, Egypt

Abstract: In manufacturing systems dealing with relatively high product mix in small batches, changeover time is one of the most critical issues that could significantly affect the responsiveness and efficiency of such production lines. Accordingly, this paper demonstrates a case study concerned with employing the Lean Six Sigma (LSS) to reduce the changeover time in a company's TV assembly line that produces different variety of models in relatively small batches to satisfy the market needs. This paper customised the value stream mapping tool such that it can be employed in analysing the changeover process itself to identify and minimise the non-value-added activities within it. The LSS implementation has resulted in identifying the dominant causes for extended changeover time and accordingly improvement countermeasures have been introduced. These improvements have resulted in a changeover time reduction from 65 minutes to 30 minutes.

Keywords: Lean Six Sigma; LSS; DMAIC methodology; value stream mapping; VSM; changeover time.

DOI: 10.1504/IJSSCA.2024.145397

International Journal of Six Sigma and Competitive Advantage, 2024 Vol.15 No.2, pp.164 - 185

Received: 30 Sep 2023
Accepted: 01 Nov 2024
Published online: 31 Mar 2025 *

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