The implementation of lean six sigma in a book manufacturing company: A case study

A book consists of cover and its contents. The finishing process of the book manufacturing is done to bind between cover and contents of the book using saddle stitcher machine. Based on a sampling conducted on March to May 2018 number of defect found in the process are 1,127 units or 0.062% during the finishing process. The assembly process mostly causes the defect product. Increasing process, there is no reference about the machine speed. Machine that run at high speed resulted in higher defects of either a set of the number of content or no sewing on the product and the cutting result is not neat so it takes time to collect the defect product and do the rework. The purpose of this research is to identify and analyze the cause of defect product and provides suggestions for quality product improvement to reduce waste defect during finishing process. Lean six sigma has the same DMAIC (Define-Measure-Analyze-Improve-Control) improvement process as six sigma, with six sigma tools and lean tools. The results of this research show that by using lean six sigma method, 3 types of defect was found, namely unkempt cutting, defect printing, and wrinkles with the average DPMO and the average sigma score of 2,886.50 and 4.26 respectively. The cutting process has the higher priority for improvement. The cause of the defect product is that there is no reference about the machine speed. The suggestion for improvement is to use simple mathematical model to determine the optimal speed of the machine to minimize relevant costs.A book consists of cover and its contents. The finishing process of the book manufacturing is done to bind between cover and contents of the book using saddle stitcher machine. Based on a sampling conducted on March to May 2018 number of defect found in the process are 1,127 units or 0.062% during the finishing process. The assembly process mostly causes the defect product. Increasing process, there is no reference about the machine speed. Machine that run at high speed resulted in higher defects of either a set of the number of content or no sewing on the product and the cutting result is not neat so it takes time to collect the defect product and do the rework. The purpose of this research is to identify and analyze the cause of defect product and provides suggestions for quality product improvement to reduce waste defect during finishing process. Lean six sigma has the same DMAIC (Define-Measure-Analyze-Improve-Control) improvement process as six sigma, with six sigma tools and lean tools. The results ...