Browsing by Author "Legesse Muchew"

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    Defect Reduction Using a Lean Six Sigma DMAIC Approach: A Case of 3F Manufacturing PLC
    (Addis Ababa University, 2023-06) Legesse Muchew; Gezahegn Tesfaye (PhD)
    Companies are forced by competitive pressures to look for ways to reduce defects while enhancing product quality. One of the best methods for corporate transformation is lean Six Sigma. This study seeks to give an empirical case study on the use of lean Six Sigma DMAIC approaches to reduce defects in a wood furniture company. The case company faces issues with the quality of its goods, which are reflected in its quality department and complaints from customers regarding the existence of defect rates of 59% in door product. Therefore, this study's objective is to reduce defects. To evaluate opportunities, present evidence for improvement, and identify possible benefits, the DMAIC technique is used in the study to look into the root causes of problems and suggest mitigation strategies. The result showed a significant decrease in the defect rate for door products. Previously, the defect rate stood at a concerning 59%; after effective interventions, it has dropped substantially to an impressive 22.96%. Through careful examination and rectification of underlying causes, it successfully identified and addressed the issues leading to defects. As a result, the number of defective doors produced has significantly decreased. Not only tackled defects but also made notable strides in improving process efficiency. The cycle time has witnessed a commendable reduction of 51 minutes, decreasing from 2114 minutes to 2063 minutes. To measure the consistency and reliability of our processes, it is important to utilize the sigma level. The sigma level has shown significant progress, improving from 2.6 to 3.2, considering a 1.5 sigma shift. This means that our process now operates within a narrower range of acceptable variations, ensuring greater consistency and reliability in the products. Even without factoring in the 1.5 sigma shift, the sigma level has improved from 1.18 to 1.7. This improvement is in terms of reducing variations and increasing process stability. With these outcomes, it is evident that Lean Six Sigma can indeed be applied for defect reduction in a furniture company, successfully reducing the defect rate, enhancing the overall quality of our products, and strengthening the reliability and consistency of our processes. During the research phase of the DMAIC process, a serious oversight was discovered; a lack of validation relative to the identified root causes. This omission may limit the achievement of intended goals and lead to ongoing processing difficulties.