Investigations on driving innovation in small size foundries through the implementation of lean six sigma principles

Abstract

quotIn Indian SME s very few papers reported on lean six sigma from science direct,Inderscience, Taylor Francis and emerald publication .out of 17 papers only 8 papers reporting the LSS implementation in Indian SME s. In Indian SME S papers reported work done in various sectors like cylinder frames manufacturing unit (Gnanaraj et al. 2011), Automobile accessories manufacturing unit (Kumar et al.(2007)), Rotary switches manufacturing organisation (Vinodh et al.2012), Automotive valves manufacturing organisation (Vinodh et al.2011), textile mill (Karthi et al.2013), frame work for An automotive component manufacturing organization( Swarnakar et al.2016),Aircraft Maintenance( karunakaran2016), and improvement of claim processing time(Mukhopadhyay and Ghosh 2013).Gujarat state satisfied the major need of cast automobile component and engine all over India and World. so author find the application of Lean Six Sigma in Foundry sector of Gujarat by developing a model and implement the model in several foundries and investigate the results of LSS in foundry .In foundry maximization of waste on floor so better result can be achieved with a proper directional training and monitoring waste on a floor and sources of major defect in casting can be identified by continuous monitoring the system as well workers as 80 percentage of problem occurs due to 20 percentage of causes. Author published a literature review paper (available in list of papers) of lean six sigma to identify this research gap in foundry. Authors identify LSS application in various sectors except foundry in literature review, so author identify foundry sector for LSS implementation and prepare a framework with a name LESSIFOUND (stands for LE-lean, SS-six-sigma, FOUND-foundry).In the context of drawing this inference, the doctoral work being presented in this thesis was carried out to implementing lean six sigma in several foundries of Gujarat. With the application of LSS in any industrial plant we can reduce the cycle time, meet the customer need, and reduce t