Author:
Wa-Muzemba Anselm Tshibangu
Affiliation:
Morgan State University, United States
Keyword(s):
Lean Six Sigma, Material Handling, Inventory Management, Process Improvement
Related
Ontology
Subjects/Areas/Topics:
Facilities Planning and Management
;
Industrial Engineering
;
Informatics in Control, Automation and Robotics
;
Lean Enterprise
;
Resources and Knowledge Management in Industry
Abstract:
This paper describes a two-step strategic-tactical Lean Six Sigma methodology as used by the author to improve productivity, enhance inventory and material handling management, and thus, reduce operational costs at “Down Town Press Inc.”, a commercial printing press located in New York State, USA. A close look at the company’s performance revealed a troubling picture with only 51 % utilization of personnel, nearly $40,000 of invested capital underutilized annually, and an excess of monthly inventory costs of almost $29,000. This study was conducted to help the company avoid a fatal bankruptcy and regain financial prosperity. First, a strategic Six Sigma DMAIC procedure approach is deployed to better understand the deep turmoil faced by Down Town Press Inc. Second, a more tactical Lean approach is applied to identify various wastes and propose a set of techniques, technologies and strategies to reduce or eliminate the identified wastes, and thus, reduce operational costs. The continu
ous improvement changes proposed at the conclusion of the study suggest a possible reduction of $300,000 in yearly operational capital. Furthermore, with the implementation of the proposed Inventory Management integrated with a comprehensive Material Handling Management System, the study predicts a higher utilization of employees and, therefore, an increased productivity.
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