Improvement of Process Manufacturing Using Lean Six Sigma Production Techniques: A Case Study in the Food Industry

Abstract

This research aimed to improve the seafood processing process using value stream mapping as a tool for data gathering and data analysis using DMAIC and implementing lean production techniques to increase productivity. A case study of the company can be summarized as follows. (define) productivity is lower than the set target of 4.26 kg/person*hour. (measure) the production line has an average productivity of 85.20%. Bottlenecks film peeling and packing process and inventory of work in process to 2,049 kg. (analyze) There are four root causes of the problem as follows: 1) Skills, 2) Machines, 3) Line balancing, and 4) Working standards (improve) ranking each root cause of the problem to impact more to less the order of importance before improvement as follows: 1) Line balancing: film unpacking and product packaging productivity average to 40.49%. 2) Machines: switch the cut position of a product productivity average to 83.79%. 3) Skills: rotate the packing position productivity average to 40.17 kg/hour. 4) Working standards define the new operating procedure productivity average to 37.68%. These research results are summarized: productivity increased on average to 14.40%. The bottleneck decreased by 70.35%. Productivity per hour increased to 18.14%. Production per person per hour increased to 53.80%. Direct labor costs decreased by 9.50%. Direct labor cost saved 33,410 baht per month.