Reduction of Setup Times in a Metal Fabrication Company Using a Lean-Sigma Approach
DOI:
https://doi.org/10.29019/enfoqueute.1027Keywords:
Problem Solution, Process Improvement, Lean-Sigma, SMED, Six-SigmaAbstract
Manufacturing companies face demand fluctuations and must deliver the required quantity of parts to their customers within the required time; however, companies face different challenges in fulfilling them. One is technological advances, which make it impossible for them to compete with other countries, such as China, due to financial issues. Therefore, manufacturing companies use continuous improvement methodologies to achieve better performance in their processes. Six Sigma and Lean Manufacturing are some of the best-known approaches. This article briefly presents the application of a lean sigma approach oriented to solving problems. This research proposes a methodology based on Lean Sigma that contrasts what different authors currently do: continuous improvement projects that take up to 12 months to produce results and do not solve a problem. This implementation is conducted in a process that manufactures metal parts and fails to deliver them on time to its customers. Using tools such as the Single Minute Exchange of Die (SMED) in a production line, on-time deliveries were increased from 89 % to 96 %; at the same time, the model change times were reduced by approximately 60 %, which is required for the implementation of this methodology for only four weeks, unlike the traditional six-sigma approach that can take up to 12 months to improve the process.
Downloads
References
S. Deeb, H. B. El Haouzi, A. Aubry and M. Dassisti, “A generic framework to support the implementation of six sigma approach in SMEs,” Elsevier B.V., Jan. 2018, pp. 921–926. https://doi.org/10.1016/j.ifacol. 2018.08.490
P. Guleria, A. Pathania, S. Sharma and J. C. Sá, “Lean six-sigma implementation in an automobile axle manufacturing industry: A case study,” Mater Today Proc, vol. 50, pp. 1739–1746, Jan. 2022, https:// doi.org/10.1016/J.MATPR.2021.09.177
H. Gholami, N. Jamil, M. Z. Mat Saman, D. Streimikiene, S. Sharif and N. Zakuan, “The application of Green Lean Six Sigma,” Bus Strategy Environ, vol. 30, no. 4, pp. 1913–1931, May 2021, https://doi. org/10.1002/bse.2724
R. S. Barot, J. Patel, B. Sharma, B. Rathod, H. Solanki and Y. Patel, “Lean six sigma feasibility and implementation aspect in cast iron foundry,” Materials Today: Proceedings, Elsevier Ltd, 2019, pp. 1084–1091. https://doi.org/10.1016/j.matpr.2020.01.087
R. Rathi, M. Singh, A. K. Verma, R. S. Gurjar, A. Singh and B. Samantha, “Identification of Lean Six Sigma barriers in automobile part manufacturing industry,” in Materials Today: Proceedings, Elsevier Ltd, 2021, pp. 728–735. https://doi.org/10.1016/j.matpr.2021.05.221
J. Singh, H. Singh and S. Kumar Gandhi, “4 7 Assessment of Implementation of Six Sigma DMAIC Approach in a Casting Unit: A Case Study Assessment of Implementation of Six Sigma DMAIC Approach in a Casting Unit: A Case Study,” 2018.
A. Aytekin et al., “Critical success factors of lean six sigma to select the most ideal critical business process using q-ROF CRITIC-ARAS technique: Case study of food business,” Expert Syst Appl, vol. 224, Aug. 2023, https://doi.org/10.1016/j.eswa.2023.120057
J. P. Costa, I. S. Lopes, and J. P. Brito, “Six Sigma application for quality improvement of the pin insertion process,” in Procedia Manufacturing, Elsevier B.V., 2019, pp. 1592–1599. https://doi.org/10.1016/j. promfg.2020.01.126
M. S. Carrillo Landazabal, J. T. Peralta Ordosgoitia, C. A. Severiche Sierra, V. P. Ortega Vélez, and L. E. Vargas Ortiz, “Reducción de ruido industrial en un proceso productivo metalmecánico: Aplicación de la metodología DMAIC de Lean Seis Sigma,” Entre ciencia e ingeniería, vol. 15, no. 30, pp. 41–48, Dec. 2021, https://doi. org/10.31908/19098367.1819.
A. Adeodu, M. G. Kanakana-Katumba and M. Rendani, “Implementation of lean six sigma for production process optimization in a paper production company,” Journal of Industrial Engineering and Management, vol. 14, no. 3, pp. 661–680, 2021, https://doi.org/10.3926/ jiem.3479
A. Mittal, P. Gupta, V. Kumar, A. Al Owad, S. Mahalwat, and S. Singh, “The performance improvement analysis using Six Sigma DMAIC methodology: A case study on Indian manufacturing company,” Heliyon, p. e14625, Mar. 2023, https://doi.org/10.1016/j.heliyon.2023. e14625
D. Zhang, S. Chen and Y. Xu, “Study on the Improvement of Single Minute Exchange of Die Based on Lean Production,” 2022, https://doi. org/10.1117/12.2645572
M. Tekin, M. Arslandere, M. Etlioğlu, Ö. Koyuncuoğlu and E. Tekin, “An application of SMED and Jidoka in lean production,” in Proceedings of the International Symposium for Production Research 2018 18, Springer, 2019, pp. 530–545. https://doi.org/10.1007/978-3-319- 92267-6_45
P. Ondra, “The Impact of Single Minute Exchange of Die and Total Productive Maintenance on Overall Equipment Effectiveness,” Journal of Competitiveness, 2022, https://doi.org/10.7441/joc.2022.03.07.
D. Agung and H. Hasbullah, “Reducing the product changeover time using SMED and 5s methods in the injection molding industry,” Sinergi, 2019, https://doi.org/10.22441/sinergi.2019.3.004
“Index.” Accessed: Jan. 29, 2024. [Online]. Available: https://index. org.mx/
S. D. Kulkarni et al., “Enhancing the process capability of machining process of boring tool holder by application of six sigma methodology,” Mater Today Proc, vol. 52, pp. 329–338, 2022, https://doi. org/10.1007/978-3-319-92267-6_45
S. Nallusamy and V. Saravanan, “Lean tools execution in a small scale manufacturing industry for productivity improvement-A case study,” Indian J Sci Technol, vol. 9, no. 35, pp. 1–7, 2016. https://doi. org/10.17485/ijst/2016/v9i35/100162
F. Estrada-Orantes and N. Alba-Baena, “Creating the lean-sigma synergy,” in Lean manufacturing in the developing world: methodology, case studies and trends from Latin America, 2014, pp. 117–134. https://doi.org/https://doi.org/10.1007/978-3-319-04951-9_6.
O. C. Gracia, F. J. E. Orantes and F. H. Pérez, “Aplicación de la metodología Lean-Sigma en la solución de problemas en procesos de manufactura: Caso de Estudio,” Cultura Científica y Tecnológica, no. 57, 2016.
Published
How to Cite
Issue
Section
License
Copyright (c) 2024 The Authors
This work is licensed under a Creative Commons Attribution 3.0 Unported License.
The articles and research published by the UTE University are carried out under the Open Access regime in electronic format. This means that all content is freely available without charge to the user or his/her institution. Users are allowed to read, download, copy, distribute, print, search, or link to the full texts of the articles, or use them for any other lawful purpose, without asking prior permission from the publisher or the author. This is in accordance with the BOAI definition of open access. By submitting an article to any of the scientific journals of the UTE University, the author or authors accept these conditions.
The UTE applies the Creative Commons Attribution (CC-BY) license to articles in its scientific journals. Under this open access license, as an author you agree that anyone may reuse your article in whole or in part for any purpose, free of charge, including commercial purposes. Anyone can copy, distribute or reuse the content as long as the author and original source are correctly cited. This facilitates freedom of reuse and also ensures that content can be extracted without barriers for research needs.
This work is licensed under a Creative Commons Attribution 3.0 International (CC BY 3.0).
The Enfoque UTE journal guarantees and declares that authors always retain all copyrights and full publishing rights without restrictions [© The Author(s)]. Acknowledgment (BY): Any exploitation of the work is allowed, including a commercial purpose, as well as the creation of derivative works, the distribution of which is also allowed without any restriction.
Enfoque UTE - Facultad de Ciencias de la Ingeniería e Industrias - Universidad UTE
