Applying Tools of Lean – Six Sigma Method in the Plastic Products Industry: A Case Study

This study aims to provide an overview of the problems, the causes that occur, and some suitable solutions as planning the maintenance time of the screws holding the bellows holder in the extrusion stage, creating a standardized for spray manipulation in the extrusion stage, re-layout the inventory, creating the visual management of the defect control process to reduce waste, prevent and minimize the risks of the defective product and help workers conduct task quickly and efficiently by applying the DMAIC model (Define, Measure, Analyze, Improve, and Control) with supported tools such as Seven wastes, Cause and effect diagram, Pareto chart, 5S, Visual management. Further, a case study on the Plastic Company is discussed, emphasizing the production process area. The result obtained was that the time for searching measuring instruments during production was reduced by 95.8%, the maximum material capacity in the warehouse increased by 13.8%, the aisle area in the warehouse increased by 19.6%, time taken by staff to get materials from the warehouse decreased by 2.27%.