An application of lean six sigma techniques to accelerate the implementation of Kaizen in the film packaging industry

Abstract

The integration of lean six sigma techniques in manufacturing results in substantial improvement and hence a more profitable organization. The case study company is based in South Africa and specialises in manufacturing plastic film, which uses thin micron plastic for food packaging. The main goal of this research was to accelerate the rate of kaizen implementation by utilizing lean six sigma techniques in order to construct a semi-automated model. Lean six sigma is comprised of various problem-solving techniques. In this case study, 5Whys was combined with Ishikawa to construct a semi- automated model for an effective defect trouble shooting closure system. Defect trouble shooting system is also called a “non-conformance closure system”. It was evaluated that the procedure of non-conformance closure at the company was inadequate; this was identified as a major finding during an external ISO audit. An opportunity to utilize lean techniques was identified and implemented in order to satisfy the objectives of this research. The first objective was to define the requirements of ISO standards in order to find a suitable system that could be used. Defining the requirements was key for the researcher to get an idea of how the model should be constructed to suit ISO standard requirements. The second objective was to evaluate the current method and find the root cause of the problem; this objective highlighted all the possible causes that had resulted in an inadequate procedure for non-conformance closure. The third objective was to construct a model by integrating lean techniques that matched ISO standards. This objective was implemented in order to satisfy the research goals; a semi-automated model resulted in a catalyst for continual improvement. The fourth objective was to implement the semi-automated model on each non-conformance that was raised and the fifth objective was to reflect by monitoring and recording the results from the semi-automated model. This method resulted in a smooth flow system of non- conformance closure; the major finding closure was accepted after the auditors monitored the new semi-automated method. Automated non-conformance software, which integrates any system that needs corrective action, was recommended, and seven types of waste were recommended for further analysis. This semi-automated model can be used as a future programme parameter for completing an automated system to resolve non-conformances.