Waste Analysis in the Aluminum Extrusion Process utilizing Lean Six Sigma and Failure Mode Effect Analysis (FMEA)
DOI:
https://doi.org/10.24235/itej.v11i1.293Keywords:
Aluminum Extrusion, Lean Six Sigma, FMEA, Seven WasteAbstract
This study aims to identify dominant waste types, analyze the root causes of quality failures, and formulate improvement recommendations to enhance production process efficiency. The methodology integrates Lean Six Sigma and Failure Mode and Effect Analysis (FMEA). Unlike previous studies that focus on a single CTQ in aluminum extrusion processes, this study addresses four dominant CTQs using an integrated Lean Six Sigma and FMEA approach to provide a more comprehensive quality improvement framework. Identification results reveal that defect is the most critical waste, with the highest weight of 0.1206, followed by waiting at 0.0905 and transportation at 0.0854. Root cause analysis of product defects using fishbone diagrams and FMEA indicates that denting poses the highest risk, with a Risk Priority Number (RPN) of 336. Through the proposed improvement designs, the company can entirely eliminate non-value-added (NVA) activities and significantly reduce necessary non-value-added (NNVA) activities. The implementation of these recommendations successfully reduced the total lead time from 2,435.59 minutes to 1,870.41 minutes, resulting in an increase in the Value-Added (VA) time percentage from 40.86% to 46.34%.
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