Application On Integration Of Lean Thinking And Six Sigma Method In Tape Production Line

To get advantage in the more and more competitive market, MM company has been using 6 Sigma management method to control cost and reduce waste all along. But the fact shows that the result is not satisfactory. So management of tape production line has made decision to try other more effective analysis method.After careful analysis of weakness and advantage of both Lean Tool and Six Sigma management method, author proposes that the method- the integration of Lean thinking and Six Sigma- is a best choice to analyze complicated system. Its feasibility is firstly proved theoretically. Then a solid implementation solution is given, which is demonstrated further in the following case of tape production line by author. By this way, the effectiveness of this method is also attested to.The concrete steps go like this. Firstly, current value stream map of tape production line is drawn. Secondly, Six Sigma method is used to analyze all inputs of every process step and then key inputs which are considered as improvement opportunities are selected. Thirdly, should-be value stream map is worked out based on"Pull"system requirement and lean thinking. At last, wastes are detected by comparing current value stream map and should-be value stream map. Of course, targets and orientation of improvement are also decided. Afterwards, according to above mentioned analysis result, projects have been purposely initiated in four aspects- taking SMI into action, setting up KANBAN system, choosing preferable glue ingredients usage and changing business operation model.As a result, PCE (process cycle efficiency) has been improved about 30% without hurting OTIF (On-Time-In-Full) - a measurement against service level. Eventually at the end of this paper, author gives the reason why the result is so impressive. That is the big success is the result of breakthrough in changing original operation model and traditional thinking pattern.