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.
