| Abstract [eng] |
Lean Six Sigma is a methodology used for process cycle efficiency improvement and defect reduction by using quality control tools in conjunction with lean tools. During research, it was noticed that there were gaps for DMAIC applications for manufacturers who produce electronic devices and electronic component production processes. Therefore, LSS with the DMAIC has been used to analyze an electronic part manufacturing process in a smart water meter manufacturer. Furthermore, the structured analysis method has been proven to be beneficial as root causes of inefficient process cycle activities were found in the automated battery soldering operation. Suggestions to eliminate non- value-added activities were proposed as the root cause was found to be the defects generated from the soldering station needing rework, thus increasing the cycle time of the operation. Therefore, suggestions for process improvement were implemented by changing out the solder material, creating quality control procedures for new solder material batches, and improving warehousing conditions. Moreover, setup time has also been improved by eliminating walking time by introducing improvements in the workstation layout. After implementing suggestions, the process cycle efficiency has been improved by 5.26% as the daily output throughout 3 shifts improved by 21.28%, leading to 1659.85 EU monthly savings. In addition to financial benefit, the creation of standard operating procedures and 5S implementation were utilized to improve variation, uncertainty, and doubtfulness from the operators, thus providing social benefit. After analysis and improvements, it was shown that Lean Six Sigma can be utilized for electronic product manufacturers, not limited to being only used in textile, automotive parts, food, health providers, and service provider industries for production process cycle efficiency improvement. |
