Waste and Cost Reduction for a Water Bottling Process Using Lean Six Sigma

##plugins.themes.bootstrap3.article.main##

  •   Ovundah King Wofuru-Nyenke

  •   Barinyima Nkoi

  •   Felix Ezekiel Oparadike

Abstract

In this paper, Lean Six Sigma tools and techniques were utilized to determine the root causes of waste in a water bottling process and proffer solutions to remove these sources of waste in order to produce only standard quality items with minimal to zero waste generated, and also to attain a reduction in production cost. The Value Stream Map (VSM) tool was used to highlight the sources of waste in the current state of operations at the plant, as well as to proffer an improved future state of the production processes at the plant. Also, the Define-Measure-Analyze-Improve-Control (DMAIC) framework of Lean Six Sigma methodology was employed to statistically analyze the root causes of waste in the plant. The analysis showed that the major sources of waste which constitute approximately 80 per cent of waste in the plant are water volume variation, alignment error in the shrink wrapping machine and manual inspection. After implementation of the proposed solutions, manufacturing lead time and cycle time are expected to reduce by approximately 42.1 per cent and 22.2 per cent respectively, with a reduction of 2 quality inspectors in the bottling process, leading to a drop in labour cost.


Keywords: Lean Six Sigma, Value Stream Map, Waste Reduction, Water bottling

References

Sayer, N.J. and Williams, B. (2012). Lean for Dummies. 2nd ed., New Jersey: John Wiley & Sons, Ltd.

Simpson, D.F. and Power, D.J. (2005). Use the Supply Relationship to Develop Lean and Green Suppliers. Supply Chain Management: An International Journal. 10(1), 60 – 68.

Comm, C.L. and Mathaisel, D.F.X. (2000). A Paradigm for Benchmarking Lean Initiatives for Quality Improvement. Benchmarking: An International Journal. 7(2), 118 – 127.

Alukal, G. (2003). Create a Lean, Mean Machine. Quality Progress. 36(4), 29 – 34.

Lilly, M.T., Ogaji, S.O.T. and Probert, S.D. (2015). Manufacturing: Engineering, Management and Marketing. Partridge publishing.

Arthur, J. (2011). Lean Six Sigma Demystified. 2nd ed., New York: McGraw-Hill.

Kwak, Y. and Anbari, F. (2006). Benefits, obstacles, and future of Six Sigma approach. Technovation. 26(5). 708 – 715.

Cloete, B. and Bester, A. (2012). A Lean Six Sigma Approach to the Improvement of the Selenium Analysis Method. The Onderstepoort Journal of Veterinary Research. 79, 1 – 13.

Mousa, A. (2013). Lean, Six Sigma and Lean Six Sigma Overview. International Journal of Scientific & Engineering Research. 4(5), 1137 – 1153.

Furterer, S.L. (2009). Lean Six Sigma in Service: Applications and Case Studies. Boca Raton: CRC Press.

Gupta, V., Acharya, P. and Patwardhan, M. (2013). A Strategic and Operational Approach to Assess the Lean Performance in Radial Tyre Manufacturing in India: A Case Based Study. International Journal of Productivity and Performance Management. 62(6), 634 – 651.

Morgan, J. and Brenig-Jones, M. (2012). Lean Six Sigma For Dummies. 2nd ed. Chichester: John Wiley & Sons, Ltd.

George, M.L., Rowlands, D., Price, M. and Maxey, J. (2005). The Lean Six Sigma Pocket Toolbook: A Quick Reference Guide to Nearly 100 Tools for Improving Process Quality, Speed, and Complexity. New York: McGraw-Hill.

Downloads

Download data is not yet available.

##plugins.themes.bootstrap3.article.details##

How to Cite
[1]
Wofuru-Nyenke, O., Nkoi, B. and Oparadike, F. 2019. Waste and Cost Reduction for a Water Bottling Process Using Lean Six Sigma. European Journal of Engineering and Technology Research. 4, 12 (Dec. 2019), 71-77. DOI:https://doi.org/10.24018/ejers.2019.4.12.1682.