Six Sigma and Lean Manufacturing - A Merger for Worldclass Performance, but is it Really Talking Place?

Kroslid, Dag The Korean Society for Quality Management 2001 The Asian Journal on Quality Vol.2 No.1

More than a decade after their development and first wave of deployment, Six Sigma and Lean Manufacturing have recently returned on the corporate agendas of a larger number of corporations across industries and supply chains. In the wake of their re-surge, this commentary addresses the evolution, context, content and deployment patterns of the two distinct management concepts. It also analyses claims in the business press that a merger is taking place between Six Sigma and Lean Manufacturing. Here, it is found that there is not enough evidence to broadly support such claims, and it is only concluded that there is some evidence of an early tend towards a merger and that a possible merger would have many synergies and advantages. Finally, an example from a Scandinavian manufacturing company is provided that explains how Six Sigma and Lean Manufacturing can be used in a beneficial way for companies to reach world-class performance.

Structural Equation Modelling based Empirical Analysis of Operational and Technological Factors for Lean Implementation

Protik Basu,Pranab K Dan 대한산업공학회 2018 Industrial Engineeering & Management Systems Vol.17 No.4

This study attempts to explore the impact of operational and technological factors (OTFs) towards successful implementationof lean manufacturing (LM). Based on extensive literature survey, the authors endeavoured to develop anexhaustive list of all the input manifests related to the OTFs necessary for LM implementation, coupled with a similarexhaustive list of the benefits likely to be accrued from the successful implementation of LM. The critical analysis ofcollected data identified seven key input constructs and three output constructs which should act in unison to maximizethe benefits of implementing lean. Through the structural model presented in this paper, nine hypotheses were proposedand tested for validation by the data collected from Indian manufacturing companies. Seven hypotheses werevalidated while two hypotheses were not supported. Reasons behind the non-acceptance of the two hypotheses havebeen explored and mentioned. This structural model can be considered as a guide to integrate the OTFs to successfullyimplement lean. The novelty of this work lies in the fact that this is one of the very rare studies that attempted to havea survey-based empirical analysis for evaluating the impact of such factors towards an effective lean implementationin the Indian manufacturing sector.

가치흐름지도법을 이용한 린 제조공정 구축 사례

조대희(Daehee Cho),이지수(Jisoo Lee),이강원(Kangwon Lee) 한국SCM학회 2015 한국SCM학회지 Vol.15 No.1

Although value stream mapping is a well known methodology to implement lean manufacturing, cases of applying this methodology to Korean enterprises are rarely reported. This paper deals with a case of applying value streaming mapping for implementing lean manufacturing in a small enterprise which produces components for TV assembly. Using information collected in a current shop flow, a current value stream map was drawn and kaizen burst was identified. Then a future value stream map was developed and various kaizen events were applied to implement a lean manufacturing. As a result of this implementation, the KPI’s were drastically improved.

현대자동차의 기민한 생산방식: 또 하나의 베스트 프랙티스?

조형제 한국사회과학연구회 2015 동향과 전망 Vol.- No.93

Hyundai Motor Company is an unique case that has succeeded in becominga major automobile company with its own models in the world automobileindustry since the World War II. This success has been mainly due to thecharacteristics of its own production system rather than external factorssuch as government policies or exchange rates. Hyundai Motor Companyhas developed the “Agile Manufacturing” that is distinguished from the leanmanufacturing of Japanese automobile companies. Companies need to display “agility” that responds to the rapidly changingand complicating demands under the precarious environment of managementin the 21st century. Hyundai Motor Company has been a case that succeedin fulfilling agility. Hyundai Motor Company has demonstrated agilityin its value chain that is composed of product development, production,parts supply, and marketing. As the result of its agile manufacturing,Hyundai Motor Company has shown excellent performance in terms ofproduct development period and the number of vehicles per platform. 2차 대전 이후 고유모델을 개발하여 국제경쟁력을 갖는 데 성공한 완성차업체의사례는 한국의 현대차가 유일하다. 현대차의 고도성장은 정부 정책이나 환율 변동 등의 외부적 요인보다는 현대차 생산방식의 형성과 발전이라는 내부적 요인에 의해 이루어진 바가 크다. 현대차는 일본 완성차업체의 린(lean) 생산방식과는 뚜렷하게 구분되는 ‘기민한(agile)’ 생산방식을 발전시켜 왔다. 21세기의 불확실한 경영 환경에서는 세분화되고 급변하는 수요에 신속하고 능동적으로 대응하는 기업들의 ‘기민함(agility)’이 요구된다. 이러한 경영 환경 하에서 현대차는 기민한 생산방식을 선도적으로 구현하면서 두각을 나타내고 있다. 현대차의 기민함은 제품개발, 생산과정, 부품공급, 조직능력, 마케팅 등 가치사슬 전반에 걸쳐 실현되고 있으며, 제품개발 기간, 플랫폼 대비 모델 수 등의 지표를 통해 경험적으로 확인된다.

Big Y 융합 VSM을 이용한 린식스시그마 모형연구

황재문 ( Jae Moon Hwang ),김지관 ( Jie Kwan Kim ) 대한설비관리학회 2007 대한설비관리학회지 Vol.12 No.3

제조전략이 제조성과에 미치는 영향에 관한 연구 -린 생산 활동의 매개역할을 중심으로-

홍영락 ( Young Lak Hong ),박종우 ( Jong Woo Park ) 한국생산성학회 2010 生産性論集 Vol.24 No.4

This research is to examine the fit of Lean Manufacturing Practices in mediating the relationship between manufacturing strategy and manufacturing performance. By examining Lean Manufacturing Practices in relation to manufacturing strategy, the study seek to advanced the understanding of TPS, JIT, TQM in broader context. It also resolved some controversies that appeared in the literature concerning the relationship between functional strategy and manufacturing practices and manufacturing performance. The empirical data for this study was drawn from a survey of 356 middle manager/supervisor from Korean manufacturing firms. The findings indicated that Lean Manufacturing Practices was positively and significantly related to manufacturing strategy, and it partially mediated the relationship between manufacturing strategy and weighted manufacturing performance.

Experimental Investigations to Deploy Green Manufacturing through Reduction of Waste Using Lean Tools in Electrical Components Manufacturing Company

Logesh B.,Balaji M. 한국정밀공학회 2021 International Journal of Precision Engineering and Vol.8 No.2

Lean Manufacturing tool promises product quality and assures the effective way of product production and processing. This research provides continuous involvement of lean manufacturing in all stages of the production process in identifying and eliminating waste. Electrical components manufacturing involves hazardous chemical powder molding at high pressure to produce electrical switches and switchboards. This Manufacturing process involves risk for employees and the environment. Green manufacturing is the process of manufacturing and developing eco-friendly products that do not harm customers, employees and using it. Green manufacturing emphasis on environmental pollution such as wastewater management and supply, environmental protection, pollution control, regulatory compliance, recycling of wastes and other issues associated with it. Research explains the effect of green manufacturing in the electrical component manufacturing industry after the implementation of lean tools. The Relationship between lean waste and the effect of such wastes on green practices is detailed in this study. This clearly shows that, if lean wastes are reduced during manufacturing, effects on the green environment can be reduced and thus green manufacturing is attained.

An Exploratory Study on the Implementation of Lean Manufacturing System at YTMI

Curbano, Ryan Jeffrey P. 김천대학교 2016 김천대학교 논문집 Vol.37 No.-

Lean manufacturing system is a manufacturing management strategies adapted by many firms to improve their operational performance in terms of efficiency and competitiveness. The main objective of the study is to explore the extent of implementation of lean manufacturing system and to determine the drivers and barriers of the implementation. The researcher used the purposive non random sampling in the study. Forty six (46) employees were the respondents of the study who were directly involved in lean manufacturing practices. Percentage formula and weighted mean were used to interpret the result of the study. The researcher found out that most of the respondents was age 45~50 years old, female, holding a supervisory position and more than twenty years in service. It was also found out the most useful tool in the practice lean manufacturing was the 5S. Lack of training was found to be a problem encountered during the implementation. One of the factors that greatly influenced to apply the lean system was the desire to employ world best practices. It was highly evident that increase in productivity was the success indicator of the company to continuously apply lean manufacturing system. Key words: lean manufacturing, efficiency, competitiveness, productivity, 5S

The Blind Men and the Soft Drinks Industry in the United Arab Emirates

Carrie Amani Annabi,Fatima Hassan,Islam Amer 한국유통과학회 2018 The Journal of Industrial Distribution & Business( Vol.9 No.10

Purpose – This paper explores the contribution lean makes to service levels by addressing lean thinking application in logistics process improvement within a MNC soft drinks manufacturer situated in the United Arab Emirates, and identifies the most significant sources of wastes and their interdependence and highlights key attributes of successful lean implementation. Research design, data, and methodology - This case study examines key logistics employees’ perceptions on lean methodology. Results - The results highlight the most significant types of wastes in logistical processes and illustrates ways to eliminate wastes and streamline process flow. The importance of the human role within lean methodology is also identified. Findings suggest that managers should follow both a micro and macro approach when implementing lean practices, as focusing on one waste often leads to ignoring the significance of other wastes. Conclusions - This study highlights the importance of implementing lean at both micro and macro levels and shows how staff involvement increases the efficacy of lean thinking. It offers guidance towards the efficiency of creating value stream mapping processes in situ, which considers different wastes and their interdependence. Managers with limited resources are encouraged to implement lean methodology taking cognizance of these factors.

제조 셀에서의 린 전환을 위한 부하균등화 시뮬레이션 연구

진현웅 ( Jin Hyun-woong ) 한국시스템다이내믹스학회 2018 한국시스템다이내믹스 연구 Vol.19 No.3

In recent decades, lean manufacturing caught the attention of industry and academia. Therefore many researches on the lean transformation have been published. However, the number of researches considering the measurement of the benefit of lean transformation is relatively small. This lack of research caused some hesitation in adopting lean transformation, especially in small and medium sized manufacturing companies. In this research, a simulation model which can measure the benefit of lean manufacturing will be developed so as to compare its benefits under various business environments. Among the various lean transformation tools, this paper deals with the load balancing in a manufacturing cell, which is an essential step in the lean transformation. For the simulation test, system dynamics models which are composed of the process model and the operator model have been developed. Experimental tests comparing the balanced cell with non-balanced cell are performed. Test results are analyzed and some managerial implications are derived from the test results.