Improving Utilization of Space and Productivity of Kitchen-Cabinets Door at GM Profile Company Using Lean Six Sigma Methodology رسالة ماجستير

Abstract

This study examines the impact of Lean Six Sigma methodology implementation in the industrial companies in the wood sector. It illustrates the use of this methodology in helping wood products manufacturers in effectively utilizing their resources and organizing work environment to become more productive and create an environment of continuous improvement. The importance of this study stems from the need of improving the utilization of space and productivity of kitchen-cabinets door production process at GM Profile Company in Al-Bireh (Palestine) by eliminating waste and reducing variation and waste in order to better control production processes and be able to offer competitive prices. DMAIC (Define, Measure, Analyze, Improve, and Control) improvement methodology of Lean Six Sigma was implemented in five phases to achieve the desired objectives. The problem and the critical to quality metrics were identified in the define phase using a set of tools such as SIPOC (Supplier, Input, Process, Output, and Customer), PCD (Problem Context Diagram), project charter, and critical to quality tree. Current performance was measured in the measure phase using flow chart, VSM (Value Stream Mapping), eight wastes, and quick wins. Root causes of the problems were identified using cause and effect diagram and interrelationship diagraph. The layout and the productivity of kitchen-cabinets door production process were improved using the first three phases of 5S, flow chart, and value stream mapping. The achieved results were sustained using the last two phases of 5S, flow chart, work forms, and check lists. V At the end of the improvement efforts, the productivity of the kitchen-cabinets door production process and the layout were improved resulting in the reduction of lead time to produce kitchen-cabinets doors from 428.4 minutes to 138.2 minutes while the improvements in the utilization of space resulted in organizing the work environment, reducing number of accidents by 50% (from 4 to 2), and improving the layout of the following processes: kitchen-cabinets door production process, wooden door production process, wooden profiles stapling process, and wooden mesh production process through the utilization of 16% of company’s area. Moreover inventory management was also improved through controlling raw materials purchase and storage, improving final products delivery and storage, and introducing new products. This study contributes to introducing lean Six Sigma methodology implementation in small and medium size enterprises in Palestinian industry and confirms the importance of this methodology in improving quality through eliminating wastes and reducing variation which plays a huge role in survival in the Palestinian economy that is facing many challenges.