Heavens light is our guide
Integration of Lean Six Sigma to Reduce Waste
A thesis in partial fulfillment of the requirements for the degree of
[Link]. ENGINEERING
IN
INDUSTRIAL & PRODUCTION ENGINEERING
BY
Iraj Ahmed
&
Tarun Kumer Biswas
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING
RAJSHAHI UNIVERSITY OF ENGINEERING & TECHNOLOGY
RAJSHAHI 6204, BANGLADESH
Signature of the students
.
Iraj Ahmed [075016]
Tarun Kumer Biswas [075024]
Candidates Declaration
It can be declared that the Thesis presented here is an outcome of the investigation and
hardworking carried out by the authors under the supervision of Ripon Kumar
Chakrabortty, Lecturer, of the Department of Department of Industrial & Production
Engineering, Rajshahi University of Engineering and Technology.
This Thesis is not submitted elsewhere for the award of any degree or diploma or publication.
Department of Industrial & Production Engineering
Rajshahi University of Engineering and Technology
Rajshahi-6204, Bangladesh
Signature of the students
.
Iraj Ahmed [075016]
Tarun Kumer Biswas [075024]
ACKNOWLEDGEMENT
At first we would like to express our deepest gratefulness to Almighty Allah because without
his grace and mercy it was quiet impossible to complete this thesis work. Then we would like
to give a special thank to our supervisor sir Ripon Kumar Chakrabortty, Lecturer,
Department of industrial and production Engineering, Rajshahi University of Engineering
and Technology (RUET), Bangladesh. He has helped us in all sectors in thesis work. His help
and inspiration was undoubtedly a matter of pride.
Special thanks to Dr. Md. Mosharraf Hossain, Head, Department of industrial and production
Engineering, Rajshahi University of Engineering and Technology (RUET), Banladesh for
giving important guideline about how problem can be identified and solved.
We also wish to express our deepest sense of gratitude to all of the stuffs and the workers at
Pran Agro Ltd. Natore. Special thanks to the Ice-pop department for giving us related
information about their product. Without their help and information is was quiet impossible
to complete this thesis work.
I
ABSTRACT
Now-a-days many leading manufacturing industry have started to practice Six Sigma and
Lean manufacturing. They are becoming beneficial in terms of profit by increasing the
productivity and quality of product. Six Sigma is a philosophy in which the variation of
process is reduced to an amount that the VoP becomes half of the VoC. Six Sigma focuses
mainly on the quality of the product rather than speed of the process. Lean management
removes the weakness of the Six Sigma by speeding up the process. In this study, both the
Lean and the Six Sigma have been used to decrease defects of a manufacturing industry in
Bangladesh. DMAIC (Define, Measure, Analyze, Improve, & Control) model has been used
to implement the Six Sigma and Lean philosophy. The quality of a food products of a
Bangladeshi industry have been tried to improve by reducing the defective product. The
ultimate goal of this application is make the process lean and increase the level of sigma. The
necessary preventions and recommendations for decreasing defects are presented in this
study. Here only defective items and over-processing among the seven wastes have
discussed. The further objectives of this research are implementation of Lean Six sigma for
other type of waste.
Keywords: Six Sigma management, Lean manufacturing, Waste minimization.
II
CONTENTS
Title Page no
Acknowledgement I
Abstract II
Chapter 1 1-3
Introduction 1
1.1 Motivation 2
1.2 Research Objectives 2
1.3 Problem statement 2
1.4 Methodology 3
1.5 Organization of the thesis 3
Chapter 2 4-6
Literature Review 4-6
Chapter 3 7-15
Theoretical Framework 7
3.1 Six Sigma Management 7-9
3.1.1 DMAIC Model 10-11
3.1.2 Control chart 11-12
3.1.3 Pareto Analysis 12-13
3.1.4 Cause-Effect Diagram 13
3.1.5 MCDM Approach 13
3.1.6 Quality Function Deployment (QFD) 14
3.2 Lean Manufacturing 14
3.2.1 The 5S Philosophy 14-15
3.3 The Seven Wastes in the Industrial Production 15
Chapter 4 16-17
Case Study & Data Collection 16-17
Chapter 5 18-28
Calculations 18
5.1 Define 18
5.1.1 Quality Function Deployment (QFD) 18
5.2 Measure 19
5.2.1 Control Chart 19
5.2.2Control limits calculation 20
5.3 Analysis 21
5.3.1 Causes Effect Diagram 21-23
5.3.2 Pareto Analysis 24
5.3.3 MCDM approach 25-28
Chapter 6 29
Result Analysis 29
6.1 Define 29
6.2 Measure 29
6.3 Analysis 29
6.4 Improve 29
6.5 Control 29
30
LIST OF FIGURES
Figure no: Page no
Figure 3.1: Normal distribution of 6 quality control 7
Figure 3.2: Normal curve of Three Sigma quality control 8
Figure 3.3: Six Sigma process with 1.5-Sigma shift in the mean 9
Figure 3.4: Relationship between the VoC, the VoP, and the DMAIC
model
10
Figure 3.5: Basic structure of control chart 12
Figure 3.6: Basic structure of Cause-effect diagram 13
Figure 4.1: the production layout of ice-pop department 16
Figure 5.1:QFD model showing the relationship between defects and
possible causes
18
Figure 5.2: P chart 19
Figure 5.3 (a): Cause-effect diagram for leakage 21
Figure 5.3 (b): Cause-effect diagram for black particle 21
Figure 5.3 (c):Cause-effect diagrams for without coding 22
Figure 5.3 (d):Cause-effect diagram for shortage/excess 22
Figure 5.3 (e): Cause-effect diagram for loose caps 23
Figure 5.4: Pareto Chart 24
Figure 5.5 Proposed AHP model 25
LIST OF TABLES
Tables no: Page no
Table 5.1: Data table of non-conformities of 26 days with sample size
810.
19
Table 5.2: Different types of defects percentage 24
Table 5.3: Level of preference weights 25
Table5.4: Evaluation at level 1 26
Table5.5: Average Random Index (RI) based on matrix size (adapted
by Saaty)
26
Table 5.6: For the factor method 26
Table 5.7: For the factor environment 27
Table 5.8: For the factor man 27
Table 5.9: For the factor management 27
Table 5.10: Final Evaluation 28
Chapter 7
Recommendations and Future Works 30
Conclusion 31
References 32-33
Appendix A 34