Lean Six Sigma DMAIC Approach to Improve Delivery Performance

Lean Six Sigma to Improve Performance

Abstract

Today each and every thing is available just on one click. On-time delivery, quality and cost are the globally recognized foremost business drivers. Instant delivery of quality products with reasonable price is the first priority of today’s customers and business is distinguished to fulfill this expectation of customer. Advancement in technology is growing day by day. Amazon Prime offers quick delivery of One Day to its global customers. Such type of trend has urged manufacturing industry to make fast manufacturing with high quality and low price. Defects and wastages reduction is the first move to compete on globally. Quick or On-time delivery, quality and reduced costs are attainable by reducing cycle time and eliminating defects and wastages from manufacturing processes. The aim of this study is to improve on-time delivery performance by reducing cycle time with the minimization of rejection faults of washing and dyeing processes by implementing Lean Six Sigma DMAIC approach. Through the five phases of DMAIC, different tools and techniques of six sigmas were exercised. Define phase helped to elucidate the problem, measure phase computed the frequency of rejection defects and process sigma level, analyzed phase used pareto analysis to identify vital few and fishbone diagram to find root cause of vital few, to generate possible solutions and implement best one, brainstorming and KAIZEN events were used in improve phase, and control phase devised monitoring mechanism to sustain the results .DMAIC was applied in Washing department for washing and dyeing processes. Conspicuous results were found with successful application of DMAIC. The rejection rate was reduced from 5% to 0.9% and delivery performance was improved from76% to 94%. Sigma level was enhanced from 4.1 to 4.7 and FPY was upgraded from 95% to 99%. Company saved $24593 and $73778 on monthly and quarterly basis respectively,