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Kalinangan Refereed Journal

Volume no. 27 | 2019/4
Issue no. 1


Title
PROCESS IMPROVEMENT TECHNIQUES USING LEAN MANUFACTURING TOOLS IN SIX SIGMA METHODOLOGIES AS APPLIED TO ELECTRONIC MANUFACTURING SERVICES COMPANIES’ KAIZEN PROJECTS
Author
Contreras, Marizen B., PIE, MBA, MSME; Lopez, Christer A., MSME; Solis, Jermhel M., REE, MEng
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Abstract
In this mixed (case-experimental) research design for electronic manufacturing service companies, the researchers proposed a process improvement framework for their Kaizen projects using lean manufacturing tools in Six Sigma methodologies. Analyses of the current process improvement tools were conducted to come up with a framework that could address continuous improvement, increase productivity, and reduce cost. It was done by conducting gemba walks, interviews, and document reviews in 15 electronics manufacturing companies. Based on the findings, the following tools were incorporated and utilized: in the define phase, current state analysis, pie chart, and process flow; in the measure phase, Pareto analysis; in the analyze phase, Ishikawa diagram, whywhy analysis, process mapping, process failure mode effects analysis; in the improve phase, potential solutions, data analysis, cost savings calculations; and in the control phase, control plan. The process improvement framework was then implemented in an electronic manufacturing services company chosen by the researchers. After implementation of the proposed improvement framework, scrappage was reduced. It was then concluded that a 99% improvement was achieved and the cost of remake improved by 93.22%. The proposed framework could provide significant improvement for EMS companies in terms of reduction of defective parts and increase in cost savings.
Keywords
lean manufacturing, six sigma, kaizen, electronics manufacturing services companies
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