With Lean Six Sigma To Analyze And Improve GT Company Manufacturing Process

This thesis discussed integration model of Lean and Six Sigma, and verified itsmaneuverabilty and validity in practice.Based on this, it summarized current theory of Lean manufacturing and Six Sigma,and summarized integration model of Lean and Six Sigma which was widely used inacademic and enterprise today. It analyzed current model’s weakness and created newintegration model of Lean and Six Sigma.It analyzed current industry situation and market and operation performance status.Through the backgrond introduction, it highlighted the necessary and urgency ofimproving.Through practice of new integration model of Lean and Six Sigma, identified valueand waste and found which parts could be improved; found the gap between processcapacity and customer demand, analyzed information flow, identified waste of criticalprocess and analyzed its root cause through value steam mapping; analyzed critical processsmoothness, found its bottleneck and its optimized parameter setup; identified the processwhich could be pulled, and its inventory level of minimum and maximum; anlyzedmechanism of continuous improvement, found which parts could be standardized and errorprevented, and cirtical equipments for total productive maintenance.According to above analysis, used new Lean Six Sigma model to improve the process.Reduced waste; improved process capacity, improved information flow, controlled wasteof critical process; improved bottleneck; designed and implemented inventory pull system.Collected data after process improvement and analyzed it. Through practice of LeanSix Sigma, found out critical factors impacting GT company process, and offered solutionon it. This approach systemiclly analyzed important problems in manufacturing process,and controlled and improved critical factors, thus improved manufactuing performance;improved its productivity and reducing unit cost; gained more customer orders and createdmore economic benefits; improved competence with competitors.This case could be learned by other similar firms. It analyzed new Lean Six Sigmamodel applicability and its advantages and limitation; highlighted top management andorganization influence and relative attention points for process improvement.In current samll and middle sized companies, especially for those with complexprocess, due to resource limitted, they feel hard to manage on time delivery and productsquality when orders and products are varying a lot. The management on these companiesneed face plenty of problems and feel hard to prioritize them. They lack of systemicimproving methodology. This new integration model of Lean Six Sigma could be learnedand used for them, to analyze their business, and find out the root caused and improve it.