Reducing production costs by applying Lean Six Sigma Methodology: A case study

This study describes a procedure that applies Lean Six-Sigma approach to reduce production costs in a bolts manufacturing. The project was proposed by the product’s customer, who suggests to improve some parameters of the processes associated with its manufacturing. The expectations and requirements are termed as the Voice of the Customer (VoC) focusing on the reduction of production costs. The bolts manufacturing has some particularities, such as the considerable lot-size and the high level of produced products. Some of the important Six Sigma and Lean tools were discussed which will be of help to a Six Sigma practitioner. The empirical study illustrates methods used to Define, Measure, Analyse, Improve and Control (DMAIC) approach of Six-Sigma. Detailing the practices of the five phases of the DMAIC, the Six-Sigma empirical study describes and studies the functions and the efficiency of the bolts manufacturing processes and thesame methodology can be extended to numerous other examples in the industry.

Rui M.F. Dias is PhD in Industrial Management student from FCT-UNL, with MBA in Management from FEUC in 2009 and degree in Chemical Industry from FCTUC in 1987. Industrial Manager in Equipar – A&I since 2009. Interests area are Quality Management, Operation Management, Food Safety, Lean, Six Sigma and Theory of Constrains.

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Bolts manufacturing; DMAIC methodology; Lean Six Sigma;
Voice of the Customer (VoC).