Development of Integrated Lean Six Sigma-Baldrige Framework for Manufacturing Waste Minimization: (A Case of NAS Foods Plc.)
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Date
2018-06
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Addis Ababa University
Abstract
In this research the integration of some advanced tool for waste minimization and
continuous quality improvement of biscuit industry on production process are
investigated. Nowadays, food industry makes significant contribution to national
economy in many developing countries. Here in Ethiopia less contribution in an
improvement of biscuit industry analyzed and waste minimization. There are different
wastes that are identified by Six sigma (DMAIC) on NAS food Plc.as a result the value
of waste ratio is 36.7%, this shows non lean. The defect of the company also calculated
and defect per million are 67,308. This shows that the biscuit production has a production
capability with a failure of 67,308 every 1,000,000 productions. The other problem here
is there are limited studies were conducted so far to implement waste minimization tools
like six sigma, lean and MBNQA framework. The main objective of this study is to
develop an integrated continuous quality improvement model so as to minimize waste of
biscuit process manufacturing. The lean six sigma were created to define, measure and
improve the process waste of the company in other way baldrige with six sigma were
created to define, measure and improve management perspective. The tasks were
integrated using both quantitative and qualitative analyses. As a result and improve by
using FMEA was carried out at each stage of the existing process used to determine the
failure of the process and to analyze and improve the production quality and the result of
highest RPN on Stacking and packaging process so they should take action for waste
minimization and continuous quality improvement. Also correlation and regression
analysis result by using SPSS software shown strong relation between each variance.
Lastly, it proposed continuous quality improvement model.
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Keywords
Waste Minimization, Six Sigma-Baldrige Framework, NAS Foods Plc., Manufacturing Waste Minimization