Mateen Omar Carrim, Kapil Gupta
Corresponding email: [email protected]
A B S T R A C T
This study successfully employed lean manufacturing techniques in conjunction with the DMAIC methodology to enhance the efficiency of a sweet manufacturing production line. By using key performance indicators (KPIs) and value stream mapping, we were able to quantify the improvements achieved. A notable 36% increase in Overall Equipment Effectiveness (OEE) was realized, driven by a 19.4% improvement in performance and a 17.58% increase in quality. While availability experienced a minor decline, the overall gains in performance and quality outweighed this effect. Value stream mapping revealed a significant reduction in rework from 388 kg to 273 kg per production shift, representing a substantial 30% decrease. This reduction directly contributed to a 18.8% increase in production yield, from 612 kg to 727 kg. These improvements were facilitated by the implementation of a Poka-Yoke device and targeted bottleneck analysis. The achievement of the present work encourages to extend the implementation of lean and DMAIC combined methodology to other production lines of the company.