Enhancing production efficiency , reduction of deffects and eleminating bottlnecks in production Line 01 : A combined EFESO’s problem solving system and Lean six sigma approach .

Abstract

This thesis has demonstrated the powerful impact of integrating a structured problemsolving system with Lean Six Sigma methodologies to optimize production processes. In today's competitive environment, improving both efficiency and quality is crucial, and the combination of these approaches provides a robust framework for sustainable improvement. The research has shown that using Lean Six Sigma alongside a systematic problem-solving approach helps identify and eliminate bottlenecks, reduce defects, and minimize waste, leading to significant gains in operational performance. Lean tools, such as value stream mapping and 5S, were effective in eliminating nonvalue- added activities like excess movement and waiting, resulting in more streamlined workflows and better resource use. Meanwhile, Six Sigma methods, including DMAIC and root cause analysis, focused on reducing process variability and defects, ensuring that improvements were both targeted and impactful. Together, these methodologies provided a balanced approach—improving process speed and efficiency while maintaining high-quality standards. The results from the case study revealed substantial improvements, such as increased Overall Equipment Effectiveness (OEE) and reduced defect rates. Standardizing corrective actions and implementing visual management tools across all production lines ensured that these improvements were sustained. This approach also helped instill a culture of continuous improvement, where teams are encouraged to monitor, analyze, and enhance their processes continuously.