Six Sigma DMAIC methodology has been applied to systematically apply lean manufacturing concepts and tools in order to improve productivity in a local company specialized in the manufacturing of safety and fire resistance metal doors, windows, and frames. In-depth analysis of the plant processes unfolded different critical processes, specifically foam injection process and sheet metal cutting process. Throughout the different project phases, various improvements had been implemented to reduce production cycle time from 216 min to 161 min;non-value added activities in the different processes were identified and eliminated. Plant layout and machine reconfiguration reduced backtracking and unutilized space. Percentage of defective doors (needing rework) dropped from 100% to only 15%. The successful implementation of this project is largely due to top management active involvement and participation of workers and operators in all stages of the project. Finally, new policies and mentoring programs are introduced to maintain improvements.
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