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Example Lean Six Sigma Projects In Manufacturing

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There are several areas in which Lean Six Sigma can be applied to manufacturing operations. Some examples are:

a) Reduce quality defects (scrap/rework) in manufacturing processes.

b.) Reduce manufacturing cycle time (time of order to delivery)

c) Improve employee efficiency (productivity)

d) Reduce finished goods inventory levels

e) Improve customer service performance scores

f) Reduce cost of manufacturing & assembly (supplier component costs)

g) Reduce maintenance costs (better processes)

h) Reduce warranty costs for products

i) Improve customer satisfaction scores

j) Reduce the cost of non quality

k) Reduce non-value added activities (manufacturing steps)

l) Improve equipment utilization (improve throughput)

m) Reduce work-in-process inventories between processes

n) Improve inspection procedures (sampling techniques)

o) Reduce time to meet customer requirements

p) Reduce time to develop new products (manufacturing related)

q) Improve workplace organization

r) Improve process stability / control

s) Reduce variation in manufacturing quality

t) Standardize workplace

u) Deploy process flow concepts

v) Improve employee engagement scores

w) Improve product performance by controlling critical features

x) Improve planning & forecasting of demand (supply chain issues)

y) Reduce the amount of obsolete inventory

z) Improve related transactional processes: accounting, human resources, purchasing etc.

Some of these projects are more suited for Six Sigma type projects, others are Lean type projects / processes, and some may require both Lean and Six Sigma toolkits.

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Dear Mr.Jayram,

I am newly joined to this forum.

I have done my MBA in Operations after Mech. Engg.

I am currently working as a Mgmt. Trainee in a Manufacturing Company.

Actually, I wanted to know the carrer path in this field with respest to Six Sigma.

Also, what are the opportunities & challenges.

Thanks & Regards,

Sarang Bhusari

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Dear Sarang,

Welcome to the interactive forum of Benchmark Six Sigma.

Following is the "web link" that will help you, in getting the knowledge of the "Career Path" of various Six Sigma practitioners in this industry.

Here are some 'Success Stories' on the following URL;



Chirag Kumar Gupta

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I am T.S.Gopinath has joined recently the forum. I am Leansigma Black belt from GSK Pharmaceuticals and currently working as GM - Operations . In addition to Manufacturing i am also coordinating Lean Sigma activities in the company.

To start with we have conducted Brain Storming sessions across all depts in the company and generated 1000 ideas for improvement , Selected about 50 Projects for implementation and getting cost benefits .

The areas we have focussed are,

1) cycle time reduction

2) Waste in QC sampling

3) Waste in excess material in packing more than required

4) Waste in stationary

5) Recycling of packing material

6) Energy coservation

7) Water conservation

8) Yield improvement

9) Reduction in WIP material

10) Reduction in waiting time

11)Reduction in communication wastages

12) Reduction in transportation

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Foundations of Lean principles can be traced back to Toyota Production System (TPS)

Taiichi Ohno, the founder of TPS said:

“All we are doing is looking at the time line from the moment the customer gives an order to the point when we collect cash. And we are reducing the time line by removing the non-value added wastes.â€


Objective of Lean is to increase process speed and reduce invested capital. 

Lean philosophy:

“One piece at a timeâ€

“Synchronized flowâ€

“Pull Systemâ€

“Eliminate waste†in the value stream


Objective of Six Sigma is to reduce variation


Metric:  Measure process variation 


Methodology :

Consistent use of DMAIC/DMADV model

Team based problem solving,Measurement-based process  analysis, improvement and control


Management System 

Six Sigma drives strategy execution 

Leadership, sponsorship and review

Metrics driven governance process

Engagement across the organization 







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This is Arunkumaar PM. I am new to this forum at the same time I am new to the Market also ( Now only I completing my Journey of Education). 


I am planning to enter into the field of Materials in Particular Diesel Engine Manufacture. 


Can anyone tell me, what are the defects may come in Purchase department.? and tell me the way to reduce the defect....?


Thank you

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Hi Arun, a requirement not met is a defect. So, for Purchase Department, an incoming non conforming material is a defect, non-conformities missed in receiving inspection is a defect, good material  rejected is a defect, not following the specified procedure is also a defect. It is hard to specify an action to reduce defects at this point as your action shall depend on the kind of defect and the surrounding information that you can gather when you are at the workplace.


Hope this helps. 

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Dear sir,

since we are doing calibration for the new equipment,is it required to to the linearity study.what difference linearity study has with calibration procedure

can anyone help me out



Dear Mr.Venkat,


If you are refering about the uncertainity test, this test is useful to determine the level of sesitivity of your equipment to the external factors. This test will give you information of what is the minimum level of defect your equipment can identify. This is also useful for determining your gauge R&R




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Guest Vijay Mohnani

Dear Javed,


In order to make "Lean Six Sigma Projects In Forestry & Paper Industry" clear to you
I would request you to please have look at this case study which will help you understand the Lean Six Sigma Projects in the paper industry.

Please click on this link - https://www.benchmarksixsigma.com/lean-six-sigma-in-forestry-paper-timber-nurseries/


Hope this helps!




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