Design and Implementation of a Lean Six Sigma Framework for Process Improvement: a Case Study

The purpose of this paper is to develop a Lean Six Sigma framework according to the Six Sigma systemic process improvement methodology; Define, Measure, Analyze, Improve and Control (DMAIC). It was implemented and verified at one engineering company in UAE. The results show that the process "Make-to-Order (MTO) projects" has a long lead-time. The main causes of the long lead-time are the subcontractors, the customers, and the company-implemented procedures. Using the framework, it was possible to identify the most significant reason for the long lead-time, analyze the root-cause(s), suggest three relevant solutions and select the most preferred one. Using the framework methodology the user will have a systematic approach for continues improvement. The originality of this methodology was evident in integrating and using tools related to lean-production, six-sigma, balanced scorecard, simulation and cost benefit analysis. The framework allows the user identify the process problem(s) and solve them effectively.