Implementation of Lean Six Sigma in a Manufacturing Cell of Orthopedic Devices to Reduce Waste

Abstract

Abstract - Lean practices with Six Sigma methodology has been successfully applied in many industries to ensure the reduction of wastes and improve product quality. In this case study, the proposed implementation of lean six sigma for the industry of orthopedic devices is presented to reduce major types of waste. In the measure phase, data process was collected and a value stream map was developed to serve as a guide for lean activities. In the analysis of non-value added activities, a Pareto chart was used to focus project improvements in the major type of waste to reduce cycle time. A cause and effect diagram was developed to identify main causes of waste, while in the improve phase potential solutions were generated to reduce waiting time as the major source of waste. Finally to maintain the gains of the improvements, supporting methods are proposed in control phase. Key Terms - Lean Manufacturing, Six Sigma, Value Stream Map, Waste Reduction.