The case study company produces various front and rear lightings for automobiles and motorcycles. Currently, it faces two problems, i.e. high defective rate and high inventory. Lean Six Sigma was applied as a tool to solve the first problem, whereas the other problem was managed by changing the production concept from push to pull. The results showed that after applying all new settings to the process, the defect rate was reduced from 36,361 DPPM to 3,029 DPPM. In addition, after the implementation of the Kanban system, the company achieved substantial improvement in lead time reduction by 44%, in-process inventory reduction by 42%, finished good inventory reduction by 50%, and finished good area increased by 16%.
展开▼
