Track: Lean Six Sigma Competition

Abstract

Low-volume/high-complexity industries are known for their unique designs and custom products, which require extremely flexible manufacturing processes. Flexible processes can improve quality, reduce process complexity, reduce changeover time and lead times, leading to success in the market. Lean principles are the best way to improve flexibility in these industries. However, the implementation of Lean principles depends on the type of production layout, processes, and business design. For example, a production process with a fixed demand target will require different Lean principles than a variable production process with a changing demand target. Part 2 of this paper explains the cost benefits of process improvement from Part 1 of the research. It then continues with process improvements in different complex areas to provide a clearer explanation of how lean thinking can make flexible processes from complex processes. The focus on process improvement in the paint and shipping processes was a direct result of customer feedback with respect to quality non-conformances, new customer development, and special process audits by new customers.