Integration of value stream map and strategic layout planning into DMAIC approach to improve carpeting process
Abstract: This paper presents
an implementation of the Six Sigma DMAIC approach implementing lean tools and
facilities layout techniques to reduce the occurrence of different types of
nonconformities in the carpeting process. Such carpeting process can be found
in several industries such as construction, aviation, and automotive.
Design/methodology/approach: The improvement process was built through a
sequential implementation of appropriate interconnected tools at each phase of
the DMAIC approach. Utilized tools included: Pareto analysis, control charts,
Ishikawa chart, 5-whys, failure mode and effect analysis, process capability
ratio, value stream mapping, and strategic layout planning.
Findings: The carpeting process capability, quality of the product, customer
satisfaction, and cost of poor quality were significantly improved. Explicitly,
the sigma level was improved from 2.297 to 2.886 and the defects per million
opportunities (DPMO) was reduced from 21615 to 3905.
Originality/value: This paper has approved the capability of the Six
Sigma DMAIC approach to analyze, investigate, and remove the root causes of the
carpeting (preparation-installation) process nonconformities .
Keywords: Carpeting process,
Define-Measure-Analyze-Improve-Control (DMAIC) approach, process improvement,
statistical process control, value stream mapping, and facilities planning
Author: Ayman Nagi, Safwan
Altarazi
Journal Code: jptindustrigg170006
