IMPROVING PROCESS QUALITY BY NEW LEAN SIX SIGMA METHODOLOGY FOR REVAMPING ONLINE PRODUCTION LINES TRAINING

Mohamed S. Ibrahim, Mohamed A. R. Mansour, Ahmed M. Abed

Abstract


Factories of today are stuck in severe crisis, so continually striving to improve process quality to reduce
both time and costs and add more control procedures to processes. Lean Six Sigma (LSS) derives from
Lean thinking and mathematical use of sigma in statistics as a standard deviation for measuring variability;
using DMAIC and process mapping to reduce process variation. The LSS process pervades all business
aspects such as management, design, production and customer satisfaction.
The chronic problems have a solution in the new LSS using timed place Petri net (TPPN), which is a
graphical tool used to control and model functional, information, dynamic behavior and decisions aspects
of the interrelationship between processes to understand where and how improvements might be made.
So, it help in eliminating the causes of problems that absorb resources and create no value to satisfy customer
and commensurate with his needs to reduce the discrepancies between actual and planned.
Value stream mapping (VSM) is LSS tool used to map the current state and to identify source of waste to
eliminate, and map the future state. To quantify the benefits gained from using the new LSS tool in the
value stream mapping, a TPPN model was developed to provide the VSM with online data, to get a dynamic
VSM which make a continuous system control.
This work addresses the application of LSS concepts using TPPN to the continuous production processes
sector with a focus on the ceramic industry.

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