Lean Manufacturing Implementation to Improve Process Capability and Performance

Abstract

Industries has been continuously evolving with the change in tendencies and market growth of products. To be capable of maintaining the organization competitiveness, in front of an aggressive market, production capability and cost reduction is desired. Company X is dedicated to the design and manufacturing of customizable packaging and promotional merchandise. It was identified some factors affecting the deliverables of the production floor, such as inefficient layout design. Lean manufacturing is a tool widely used by many industries to reduce waste in processes. Applying this tool into production processes, allows to reduce wastes in process and to reduce production costs and defect ratio. DMAIC (Define, Measure, Analysis, Improve and Control)was the methodology used to improve the outputs of the production floor of Company X. At the end of the project an improvement of 15% on the productivity was observed; in addition, the defect rate was reduced by 33%.Key Terms: 5’S,DMAIC,Lean Manufacturing, Waste Reduction.