Title: Continuous improvement and facility redesign through the lean DMAIC Six Sigma approach: a final assembly work unit case study from Ohio, USA

Authors: Matthew Franchetti

Addresses: Mechanical, Industrial and Manufacturing Engineering Department, The University of Toledo, 2801 W. Bancroft St., Toledo, Ohio 43606, USA

Abstract: This study proposes the use of the define, measure, analyse, improve, and control (DMAIC) Six Sigma approach with an emphasis on facility redesign to reduce costs and increase capacity for a local manufacturing company in Northwest Ohio, USA. The DMAIC approach used for the case study demonstrated a broad implementation methodology to achieve cost reductions, in this case, by nearly $243,000 per year. The paper identifies each stage of the DMAIC cycle and the Six Sigma tools that were applied, including process mapping and time studies. This paper develops a framework that can be used as a template for cost reduction and capacity enhancement training.

Keywords: DMAIC; define measure analyse improve control; six sigma; facility design; lean manufacturing; continuous improvement; case study; final assembly; USA; United States; cost reduction; capacity enhancement; training.

DOI: 10.1504/IJSSCA.2014.064253

International Journal of Six Sigma and Competitive Advantage, 2014 Vol.8 No.2, pp.83 - 94

Accepted: 04 Feb 2014
Published online: 11 Aug 2014 *

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