Application of Lean Manufacturing and Lean Six Sigma Tools to Improve Back to Back Activities in the Compression Process

Abstract

A recent opportunity regarding a product ramp up in the production schedule due to a potential product transfer requires the manufacturing area to look for creative ways to improve in order to comply with expected demand. By applying Lean Six Sigma concepts, the current process was defined, a baseline was established, and improvements were identified and executed. The results achieved due to these improvements were: average back to back cycle time in the compression area was reduced from an average of 3.7 hours to 2.87 hours for a 22% reduction and a standard deviation reduction of 91% (1.44 to 0.131 hours). These results were achieved by implementing parallel activities as well as eliminating constraints (redundant documentation and availability of tools) throughout the process. The improvements were also instrumental in achieving a potential capacity increase of an additional 1.33 lots for a work week due to additional time available. Key Terms ⎯ Baseline Establishment, Cycle Time, Improvements, Lean Manufacturing.