Using Lean Six Sigma with Value Stream Analysis for workstation design: a case study

Abstract

Many industries have been successfully implementing Lean Six Sigma (LSS) tools and the Define-Measure-Analyse-Improve-Control (DMAIC) methodology to bring continuous improvement to their productive activities. However, numerous studies show the need of a higher-level analysis, such as Value Stream Mapping (VSM), in order to identify improvement opportunities that are aligned with the long-term goals of the companies. In this thesis, there is a case study where the DMAIC framework is used to carry out a project identified during a Value Stream Analysis (VSA), which progress and facilitation is presented in the study. The case consisted in the unification of three picking workstations in one, operated by a person with intellectual disabilities. The team, using a human-centered approach, tested and implemented several Lean tools, mainly visual management, poka-yoke and waste analysis to minimize human errors. VSA and DMAIC of LSS have proven to be successful tools to improve manufacturing plants. The workstation design techniques of this study can be a guide for further projects in other sectors