| dc.description.abstract | Anticipating a surge in year-end order volumes, many companies desired to proactively prepare
their production schedules for the upcoming months, striving for the most efficient performance
within their capability. The study proposed an integrated approach of Lean Six Sigma and Value
Stream Mapping (VSM), aiming to enhance production costs and operational efficiency. A case
study on textile-fabric factory X was discussed, targeting two categories: reducing the failure cost
rate at South shopfloor from 6.4% to 5% and improving on-time delivery (OTD) from 71.7% to
80%. Results showed, firstly, improved process sigma levels by 10%, reduced defect rate, and
decreased failure cost by 19%; secondly, identified and eliminated four major Lean wastes within
bottlenecks, covering defect, inventory, transportation, and extra-processing wastes, reduced 3-day
production lead time, increased value-added ratio of 3.75%, and savings of production expenses.
For result validation, Tecnomatix Plant Simulation was adopted to demonstrate the before-after
process utilization and gained benefits of the future-state VSM. Some recommendations for future
research include prolonged time for long-term assessment and further utilization of simulation
software, such as three-dimensional (3D) feature. The study hopes to promote integrated Lean Six
Sigma, cultivate a Lean mindset, and motivate continuous improvement widespread to other
businesses in Vietnam. | en_US |
