Minimization of Defective Products in Abyssinia Tannery Industry
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Date
2019-06
Authors
Journal Title
Journal ISSN
Volume Title
Publisher
Addis Ababa University
Abstract
Producing quality product is one of the major determinants that enable manufacturing organizations
to compete in the global market. There are many causes for the occurrence of defective products.
Hence, to avoid any further problem corrective measures should be taken. The main objective of this
thesis is to develop a continuous quality improvement model that integrate lean and six sigma, which
coherently applies the principles to reduce the defect level in Abyssinia Tannery Industries. The case
study is mainly based on primary and secondary data sources and the main secondary data sources are
company record, reports and literature review. Data collected from primary data sources are process
flow, cause of defects and type of defects. And frequency of occurrence of defect, amount of lowgrade
level,
defect,
their
impact,
which
defect
affect
the
company
most
and
cost
encored
to
treat
the
defective
one etc. were collected from secondary sources. In addition, both qualitatively and
quantitatively methods used to analyze the data and by using lean and six sigma tool and techniques.
The proposed structure is built upon the existing define, measure, analyze, improve and control
structure, which is well renowned in the literature. There are multidimensional causes related to
human, machine, material, method, process and organizational factors for the occurrence of defect.
To solve the problems associated with these causes, proactive, organized and continuous quality
improvement model is required. To improve the quality by reducing defect, Integrated Continuous
quality Improvement model consisting lean and six sigma developed based on case study result. Six
Sigma and lean are related and share common grounds in terms of striving to achieve customer
satisfaction. The integration between the two approaches is lean within six-sigma type of integration
and use design of experiment and future value stream mapping for improvement purpose. Their
integration is concluded to be possible and beneficial for defect reduction in Abyssinia tannery
Description
Keywords
Lean six sigma,, leather defects, Taguchi technique, design of experiment (DOE), Continuous Improvement, wastes