Development of an improvement framework for warehouse processes using lean six sigma (DMAIC) approach. A case of third party logistics (3PL) services.

This study aims at developing an improvement framework of warehouse processes by improving process cycle efficiency using lean six sigma (DMAIC) approach. A case study method was used to illustrate the evaluation of the existing processes in the warehouse of a third party logistics company with a focus on productivity using warehouse lean tools. Data were collected based on warehouse operational areas of suppliers, customers and internally related with a focus on warehouse core processes. The optimization of the warehouse processes was based on established lean tools. Based on the warehouse evaluation, high non-value added activities were observed leading to a low process cycle efficiency of 40%. After the implementation of the lean six sigma approach, the process cycle efficiency improved of up to 70%. An improvement framework was also established for productivity across the warehouse processes to minimise waste. Lean warehousing has been used to illustrate solutions to a real-time problem of productivity which has negatively impacted on management and customer satisfaction. The study has added to lean warehousing focusing on all the warehouse processes using six sigma DMAIC approach, unlike most literature which concentrates on a specific process. Also develop a framework for the improvement of the processes.

Application of lean Six Sigma methodology using DMAIC approach for the improvement of bogie assembly process in the railcar industry.

The quest for waste reduction, quality improvement and operational efficiency during the assembly process of the railcar bogie necessitates this study. Using a case study approach, this study employs the Lean Six Sigma (LSS) approach for process improvement of the railcar bogie assembly process. Primary data relating to the assembly process such as the labour and material flow, up and down times were collected at every stage of the assembly operation. The improvement process of the assembly process featured the use of some Lean tools such as the Kaizen, Value Stream Mapping, Pareto chart, Single-Minute Exchange of Die (SMED) and 5S. The investigation of the current assembly process with the use of the LSS technique indicates that the process efficiency is low due to waste generation. The results obtained showed significant improvement in the process cycle efficiency (PCE) by 46.8%, via the implementation of the Kaizen continuous process improvement approach, 27.9% reduction in the lead-time, 59.3% increase in the value added time and 71.9% reduction in the non-value added time after the implementation of the LSS approach. The findings of this work demonstrated the feasibility of the LSS approach for waste minimisation and process performance improvement in a bid to achieve operational excellence in a manufacturing organisation.