Integration of Lean Six Sigma and Theory of Inventive Problem Solving for Minimizing Waste in Shuttlecock Industry

Rika Risma Renggarsari(1*), Annisa Kesy Garside(2), Tyas Yuli Rosiani(3), Thomy Eko Saputro(4),

(1) Industrial Engineering Department, Universitas Muhammadiyah Malang
(2) Industrial Engineering Department, Universitas Muhammadiyah Malang
(3) Industrial Engineering Department, Universitas Muhammadiyah Malang
(4) Industrial Engineering Department, Universitas Muhammadiyah Malang
(*) Corresponding Author
DOI: https://doi.org/10.23917/jiti.v22i2.23012

Abstract

In today's competitive business world, organizations are striving to improve their operations and stay ahead. Lean Six Sigma is a popular approach that helps optimize processes and reduce waste. This research focuses on using Lean Six Sigma and TRIZ together to reduce waste in the shuttlecock industry. The study uses a structured process and tools like Value Stream Mapping and Fault Tree Analysis to find and solve waste issues. The results show problems like unnecessary activities, delays, and defects in the production process. Using TRIZ, suggestions for improvements are made based on the analysis. This study shows that combining Lean Six Sigma and TRIZ can effectively reduce waste and improve processes. The findings add to our understanding of using these methods in the shuttlecock industry and offer insights for future research and improvements.

Keywords

Shuttlecock industry; Defect; Lean Six Sigma; TRIZ

Full Text:

PDF

References

Adikorley, R. D., Rothenberg, L., & Guillory, A. (2017). Lean Six Sigma applications in the textile industry: a case study. International Journal of Lean Six Sigma, 8(2), 210-224. doi:10.1108/IJLSS-03-2016-0014

Alkunsol, W. H., Sharabati, A.-A. A., AlSalhi, N. A., & El-Tamimi, H. S. (2019). Lean Six Sigma effect on Jordanian pharmaceutical industry’s performance. International Journal of Lean Six Sigma, 10(1), 23-43. doi:10.1108/IJLSS-01-2017-0003

Antony, J., Snee, R., & Hoerl, R. (2017). Lean Six Sigma: yesterday, today and tomorrow. International Journal of Quality & Reliability Management, 34(7), 1073-1093. doi:10.1108/IJQRM-03-2016-0035

Ben Ruben, R., Vinodh, S., & Asokan, P. (2017). Implementation of Lean Six Sigma framework with environmental considerations in an Indian automotive component manufacturing firm: a case study. Production Planning & Control, 28(15), 1193-1211. doi:10.1080/09537287.2017.1357215

Boangmanalu, E., Abigail, T., Sembiring, A., & Tampubolon, J. (2020). Minimizing damage of product using six sigma and triz methods. IOP Conference Series: Materials Science and Engineering, 801(1), 012101. doi:10.1088/1757-899X/801/1/012101

Cabrera, B. R., & Li, G. J. (2014, 2014). A lean-TRIZ approach for improving the performance of construction projects.

Chugani, N., Kumar, V., Garza-Reyes, J. A., Rocha-Lona, L., & Upadhyay, A. (2017). Investigating the green impact of Lean, Six Sigma and Lean Six Sigma. International Journal of Lean Six Sigma, 8(1), 7-32. doi:10.1108/IJLSS-11-2015-0043

Demirkesen, S., & Zhang, C. (2021). Lean TRIZ method to prevent safety related problems in the construction industry. J. Constr. Eng. Manag. Amp. Innov, 4(2), 68-79. doi:10.31462/jcemi.2021.02068079

Donnici, G., Frizziero, L., Liverani, A., & Leon-Cardenas, C. (2022). Design for Six Sigma and TRIZ for Inventive Design Applied to Recycle Cigarette Butts. Designs, 6(6). doi:10.3390/designs6060122

Dutt, D. (2013). Six Sigma: With Reference to Library. International journal of research in mechanical engineering and technology, 3.

Ekmekci, I., & Nebati, E. E. (2019). Triz Methodology and Applications. Procedia Computer Science, 158, 303-315. doi:https://doi.org/10.1016/j.procs.2019.09.056

Elyoussoufi, S., Mazouzi, M., & Cherrafi, A. (2022). TRIZ and LSS Integrated Models Assessment: A Holistic Model Development for Organizations’ Excellence.

Gaspersz, V. (2002). Pedoman implementasi program six sigma terintegrasi dengan ISO 9001: 2000, MBNQA, dan HACCP.

Guerrero, J. E., Leavengood, S., Gutiérrez-Pulido, H., Fuentes-Talavera, F. J., & Silva-Guzmán, J. A. (2017). Applying Lean Six Sigma in the Wood Furniture Industry: A Case Study in a Small Company. Quality Management Journal, 24(3), 6-19. doi:10.1080/10686967.2017.11918515

Harry, M., & Schroeder, R. (2000). Six Sigma, New York: Currency. In: Doubleday.

Indrawati, S., ‘Azzam, A., Adrianto, E., Miranda, S., & Prabaswari, A. D. (2020). Lean Concept Development in Fast Food Industry Using Integration of Six Sigma and TRIZ Method. IOP Conference Series: Materials Science and Engineering, 722(1), 012044. doi:10.1088/1757-899X/722/1/012044

Muruganantham, V. R., Navaneetha Krishnan, P., & Arun, K. K. (2013). Performance improvement and cost minimisation for manufacturing components in a fabrication plant by the application of Lean with TRIZ principles. International Journal of Productivity and Quality Management, 12(4), 449-465. doi:10.1504/IJPQM.2013.056737

Muruganantham, V. R., Navaneetha Krishnan, P., & Arun, K. K. (2014). Integrated application of TRIZ with lean in the manufacturing process in a machine shop for the productivity improvement. International Journal of Productivity and Quality Management, 13(4), 414-429. doi:10.1504/IJPQM.2014.062220

Noronha, A., Bhat, S., & Bhat, S. (2020). Application of Lean Six Sigma-TRIZ methodology in product development. Solid State Technology, 63(5), 658-666.

Nurcahyo, R., & Apdillah, R. (2017). Application of Lean Six Sigma and Theory of Inventive Problem Solving to Reduce Waste and Improve the Quality Motorcycle Rear Arm. Journal of Asian Scientific Research, 7(5), 176.

Nurcahyo, R., Apdillah, R., & Yadrifil. (2017). Application of Lean Six Sigma and Theory of Inventive Problem Solving to Reduce Waste and Improve the Quality Motorcycle Rear Arm. Journal of Asian Scientific Research, 7(5), 176-186. doi:10.18488/journal.2.2017.75.176.186

Pereira, A. M. H., Silva, M. R., Domingues, M. A. G., & Sá, J. C. (2019). Lean Six Sigma Approach to Improve the Production Process in the Mould Industry: a Case Study. Quality Innovation Prosperity, 23(3), 103-121. doi:10.12776/qip.v23i3.1334

Purnomo, D. H., & Lukman, M. (2020). Reduce Waste using Integration of Lean Six Sigma and TRIZ Method: A Case Study in Wood Industry. Jurnal Teknik Industri, 21(2), 139-152. doi:10.22219/JTIUMM.Vol21.No2.139-152

Purushothaman, K., & Ahmad, R. (2022). Integration of Six Sigma methodology of DMADV steps with QFD, DFMEA and TRIZ applications for image-based automated inspection system development: a case study. International Journal of Lean Six Sigma, 13(6), 1239-1276. doi:10.1108/IJLSS-05-2021-0088

Ruben, R. B., Vinodh, S., & Asokan, P. (2018). Lean Six Sigma with environmental focus: review and framework. The International Journal of Advanced Manufacturing Technology, 94(9), 4023-4037. doi:10.1007/s00170-017-1148-6

Saha, R. K., & Mahmud, F. (2022). Lean Tools and Techniques for Improving Production Performance and Waste Reduction in A Plastic Company: A Case Study.

Shokri, A. (2019). Reducing the Scrap Rate in Manufacturing SMEs Through Lean Six Sigma Methodology: An Action Research. IEEE Engineering Management Review, 47(3), 104-117. doi:10.1109/EMR.2019.2931184

Sibalija, T., & Majstorovic, V. (2009). Six Sigma–TRIZ. International Journal “Total Quality Management & Excellence, 37(1-2), 375-380.

Singh, M., & Rathi, R. (2019). A structured review of Lean Six Sigma in various industrial sectors. International Journal of Lean Six Sigma, 10(2), 622-664. doi:10.1108/IJLSS-03-2018-0018

Sojka, V., & Lepšík, P. (2020). Use of triz, and triz with other tools for process improvement: A literature review. Emerging Science Journal, 4(5), 319-335.

Soti, A., Shankar, R., & Kaushal, O. P. (2012). Six Sigma with innovation tool kit of TRIZ. International Journal of Business Innovation and Research, 6(2), 220-237. doi:10.1504/IJBIR.2012.045638

Suhardi, B., Hastuti, F. S. P., Jauhari, W. A., & Laksono, P. W. (2021). Waste reduction in barwon dining chair production process using the failure mode and effect analysis (fmea) method on CV. Valasindo Sentra Usaha. Applied Research in Science and Technology, 1(1), 1-11. doi:10.33292/areste.v1i1.3

Wang, F.-K., & Chen, K.-S. (2010). Applying Lean Six Sigma and TRIZ methodology in banking services. Total Quality Management & Business Excellence, 21(3), 301-315. doi:10.1080/14783360903553248

Wang, F.-K., Yeh, C.-T., & Chu, T.-P. (2016). Using the design for Six Sigma approach with TRIZ for new product development. Computers & Industrial Engineering, 98, 522-530. doi:https://doi.org/10.1016/j.cie.2016.06.014

Article Metrics

Abstract view(s): 311 time(s)
PDF: 150 time(s)

Refbacks

  • There are currently no refbacks.