Implementation of Lean Six Sigma for Production Process Optimization in a Paper Production Company

Purpose: This study aims at implementing lean six sigma to evaluate the productivity and manufacturing wastes in the production line of a paper company Methodology/Approach: The study is a case study in nature. The method illustrates how lean six sigma (LSS) is used to evaluate the existing production process in a paper production company with focus on productivity and manufacturing wastes. The study considered a real-time problem of customer's dissatisfaction. Gathered data were based on machine functionality (up time, down time and cycle time); materials and labour flow at every process stage of the production line. The optimization of the production process was based on lean tools like value stream mapping, process cycle efficiency, Kaizen, 5S and pareto chart Findings: Based on lean six sigma application, it was discovered that the present production performance was below standard and more manufacturing wastes were generated. The present productivity and manufacturing wastes are reported as low process cycle efficiency (23.4 %), low takt time (4.11 sec), high lead time (43200sec), high number of products not conforming to six sigma values, high down time (32.64 %) and excess labour flow (33). After the implementation of the lean six sigma tools for certain periods, there were lots of improvements in the production lines in terms of all the parameters considered. Research Limitations/ Implications: The study has demonstrated application of lean six sigma in the case of solving real-time problems of productivity and manufacturing wastes which have a direct implication on customer's satisfaction. The lesson learnt and implications presented can still be further modeled using some lean based software for validity Originality/Value: The study has contributed to the body of knowledge in the field of LSS with focus to process-based manufacturing, unlike most literature in the field which concentrated more on discrete based manufacturing