5 stages improvement model (5SIM) for integrating lean manufacturing and six sigma DMAIC
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Date
2007-06
Authors
Yeap, Tee Khoon
Journal Title
Journal ISSN
Volume Title
Publisher
Universiti Sains Malaysia
Abstract
At the dawning of the twenty first century, the world economy had become
more open to competition as it had been for the past centuries. Fueled by
advancement of technology, communication and deregulated trade and
transportation, low cost countries around the globe had taken the advantage
on this access to compete with high cost countries on all fronts of industries.
Malaysia, a country which has been enjoying the industrial boom for the past
three decades, was no longer a low cost region. For the past few years, it had
experienced a steady decline in manufacturing jobs opportunities and facilities
close down had been a common sight in the local industrial sector. Based on
this scenario, this research was triggered as an effort to curb the attrition of
manufacturing businesses out of Malaysia by improving the competitiveness of
the Malaysian industry. In doing so, this research applied a business process
improvement model (the 5SIM- 5 Stages Improvement Model) based on Lean
Manufacturing and Six Sigma tools and techniques. The research covered the
details and objectives of each stage of the model, and a comprehensive
survey on Lean Six Sigma efforts that had been done to date. Also included in
this research was the execution of two case studies based on the 5SIM
business process in a manufacturing facility in Malaysia. The case studies
results comparison were done to show an interesting finding where based on
the same model, business process, environment, objective, tools and
techniques, the team's skill set composition would greatly affect the execution
of the project, but still aehieved the same goaf uttimatefy. The lesson learnt
from these two case studies were also elaborated and discussed extensively
to serve as a benchmark and guidelines for others who would like to embark
on a Lean Six Sigma journey to keep their organization competitive and
healthy. As both case studies had successfully validated the 5SIM model,
future work continuation was to expand the 5SIM business process beyond the
boundaries and move towards other areas of the supply chain .
Description
Keywords
Manufacturing and Six Sigma tools and techniques