Lean 6 Sigma Project with DMAICR for Process Loss Reduction

Abstract

This paper aims to evaluate the application of concepts related to Lean Manufacturing and 6 Sigma in a company that manufactures steel chemical cans. The Lean 6 Sigma project focused on the company's assembly sector, where process losses had a high operating cost and consequently reflected in the selling price of the products. The first step was to understand how much the process losses represented in terms of costs for the company and from that point a production line and a product were chosen, being the line that had the highest losses and the most manufactured product in the analyzed period. as a basis for analysis throughout the project. For such analysis, we used tools such as Value Stream Mapping, SIPOC, CEP, Flowchart, Ishikawa, Pareto, Measurement System Analysis, Boxplot, and others supported by the DMAICR methodology and concepts related to Lean Manufacturing, such as waste reduction, Kaizen and the 5S. After analysis, critical situations were identified involving line cutting equipment as well as process controls that were not being made.