Manufacturing companies in Singapore face increasing operational challenges due to limited space, manpower constraints, and demand variability, often resulting in production delays and inefficient material flow. This study examines how inventory management systems, production layout orientation, and lean principles can be applied to improve operational efficiency within an assembly line. Using a case study approach, the research focuses on a Singapore-based life sciences manufacturing facility, referred to as Company T. The study adopts the Lean Six Sigma Define, Measure, Analyse, Improve, and Control (DMAIC) framework to structure the improvement process. Data was collected through time studies, process observations, and Value Stream Mapping (VSM) to establish the current operational state. Root cause analysis was conducted using a Fishbone Diagram to identify contributors to inefficiencies, including inventory shortages, layout constraints, and inconsistent task execution. Improvement initiatives, such as a U-shaped layout redesign, supermarket shelving systems, dual racks at workstations, and line balancing based on takt time were proposed and evaluated. The findings indicate improved material accessibility, smoother production flow, and increased technician efficiency. The proposed solutions achieved an estimated 18.3% reduction in cycle time, annual time savings of approximately 1.5 hours per 600 units, and hard cost savings of USD 60,000x. These improvements were reinforced through control measures including standardised work, 5S (Sort, Set in Order, Shine, Standardise and Sustain) housekeeping practices, and performance monitoring.

Keywords

Lean Six Sigma, Manufacturing Operations Improvement, Assembly Line Optimisation, Facility Layout and Material Flow, Operations Excellence