Speaker
Description
An operational efficiency of any production line could be improved through Lean Six Sigma (LSS) methodologies by using Define, Measure, Analyze, Improve and Control (DMAIC) approach. The analysis could be further enhanced with an integration with risk assessment method powered by monte carlo simulation. Company A, a frozen food industry in Kedah, Malaysia is facing bottleneck processes at two main processes i.e. stamping and frying stations. A thorough analysis by utilizing work study and takt time study of Value-Added Activities (VAA),Non-Value-Added Activities (NVAA) contributed by production wastes, and risk assessment are performed. LSS tools such as Failure Mode and Effect Analysis (FMEA) is integrated with risk assessment tool using statistical analysis in @Risk software. Kaizen implementation for continuous improvement and strategic changes were carried out at the bottleneck processes. For a post-intervention, takt time measurements were revisited, revealing a significant improvement. The integration of LSS culminated in the development of Standard Operating Procedures (SOP) and Statistical Process Control (SPC), providing a framework for sustaining the productivity. The outcomes highlight the effectiveness of LSS in increasing operational efficiency, reducing production costs, reducing waste and variation, and improving product quality to satisfy customer's needs. This project contributes not only to process optimization in the food industry but also underscores the potential for continuous improvement and production waste reduction through LSS methodologies.
