IDEAS home Printed from https://ideas.repec.org/a/spr/ijsaem/v14y2023i5d10.1007_s13198-023-01980-7.html
   My bibliography  Save this article

Integration of Lean Six Sigma with Internet of Things (IoT) for productivity improvement: a case study of contactor manufacturing industry

Author

Listed:
  • Santosh B. Rane

    (Sardar Patel College of Engineering)

  • Sandesh Wavhal

    (Sardar Patel College of Engineering)

  • Prathamesh R. Potdar

    (Parul Institute of Technology)

Abstract

In today's era of digitalization and competitive market environment, organizations are more focused on manufacturing quality products at optimum cost to capture maximum business as a variety of options are available to customers for purchasing goods and services. In this scenario, the latest technologies-based productivity improvement can help organizations to achieve set targets of production and ensure the quality of products. In this study, the contactor manufacturing industry has been considered to demonstrate integrated Lean Six Sigma with the Internet of Things (IoT) approach for productivity improvement. A systematic literature survey was performed to understand the concept of Lean Six Sigma (LSS), Define Measure Analysis Improve Control approach and IoT technology. The implementation of the LSS approach reduced the rejection rate of contactors and saved the total production cost (Rs. 51,88,260/-) annually. The annual consumption of grinding wheels has been reduced by 8 quantities to produce the same quantity of contactors. The surface quality of magnets has been identified as a root cause for contactor rejections as it contributes 53.4% of total rejections. The improvement measures are recommended based on the expert's suggestions as grinding wheel dressing must be performed after the completion of a batch of 20,000 parts. The condition monitoring and IoT approach implementation are done by monitoring grinding speed (650–950 RPM), grinding wheel thickness reduction by 0.4–0.6 mm after dressing and dressing of grinding wheel after completion of 20,000 for reducing rejections. This study concluded that industries should implement the Lean Six Sigma approach with the latest technologies and appropriate tools at each stage to set processes to world-class standards and industries should identify opportunities for process and product improvement.

Suggested Citation

  • Santosh B. Rane & Sandesh Wavhal & Prathamesh R. Potdar, 2023. "Integration of Lean Six Sigma with Internet of Things (IoT) for productivity improvement: a case study of contactor manufacturing industry," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 14(5), pages 1990-2018, October.
    • Handle: RePEc:spr:ijsaem:v:14:y:2023:i:5:d:10.1007_s13198-023-01980-7
    DOI: 10.1007/s13198-023-01980-7
    as

    Download full text from publisher

    File URL: http://link.springer.com/10.1007/s13198-023-01980-7
    File Function: Abstract
    Download Restriction: Access to the full text of the articles in this series is restricted.
    File URL: https://libkey.io/10.1007/s13198-023-01980-7?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    1. I.S. Stephan Thangaiah & Vinay Sharma & Vembar Nainar Sundharam, 2018. "Analysing of customer feedback on critical quality parameters to improve productivity in manufacturing - a case study," International Journal of Productivity and Quality Management, Inderscience Enterprises Ltd, vol. 23(3), pages 349-368.
    2. Jiju Antony, 2012. "A SWOT analysis on Six Sigma: some perspectives from leading academics and practitioners," International Journal of Productivity and Performance Management, Emerald Group Publishing Limited, vol. 61(6), pages 691-698, July.
    3. Shlomo Globerson & Gad Vitner, 2019. "Measuring productivity in multi-stage, multi-product environment," International Journal of Productivity and Quality Management, Inderscience Enterprises Ltd, vol. 26(3), pages 290-304.
    4. M.L. Meena & R. Jain & P. Kumar & S. Gupta & G.S. Dangayach, 2018. "Process improvement in an Indian automotive part manufacturing company: a case study," International Journal of Productivity and Quality Management, Inderscience Enterprises Ltd, vol. 23(4), pages 524-551.
    5. Santosh B. Rane & Milind Shrikant Kirkire, 2017. "Interpretive structural modelling of risk sources in medical device development process," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 8(1), pages 451-464, January.
    6. Zhong, Xiaobo & Xu, Yuanwu & Liu, Yanlin & Wu, Xiaolong & Zhao, Dongqi & Zheng, Yi & Jiang, Jianhua & Deng, Zhonghua & Fu, Xiaowei & Li, Xi, 2020. "Root cause analysis and diagnosis of solid oxide fuel cell system oscillations based on data and topology-based model," Applied Energy, Elsevier, vol. 267(C).
    7. Santosh B. Rane & Yahya A. M. Narvel, 2016. "Reliability assessment and improvement of air circuit breaker (ACB) mechanism by identifying and eliminating the root causes," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 7(1), pages 305-321, December.
    8. Sainath G. Bidikar & Santosh B. Rane & Prathamesh R. Potdar, 2022. "Product development using Design for Six Sigma approach: case study in switchgear industry," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 13(1), pages 203-230, February.
    9. Santosh B. Rane & Nandkumar Mishra, 2018. "Roadmap for business analytics implementation using DIPPS model for sustainable business excellence: case studies from the multiple fields," International Journal of Business Excellence, Inderscience Enterprises Ltd, vol. 15(3), pages 308-334.
    10. Fikri Dweiri & Samar Ishaq, 2020. "Cable insulation productivity improvement using Lean Six Sigma," International Journal of Productivity and Quality Management, Inderscience Enterprises Ltd, vol. 30(4), pages 488-508.
    11. Pardeep Gupta & Sachit Vardhan, 2016. "Optimizing OEE, productivity and production cost for improving sales volume in an automobile industry through TPM: a case study," International Journal of Production Research, Taylor & Francis Journals, vol. 54(10), pages 2976-2988, May.
    12. Jiju Antony, 2012. "A SWOT analysis on Six Sigma: some perspectives from leading academics and practitioners," International Journal of Productivity and Performance Management, Emerald Group Publishing Limited, vol. 61(6), pages 691-698, July.
    13. Harsha Pandey & Dixit Garg & Sunil Luthra, 2018. "Identification and ranking of enablers of green lean Six Sigma implementation using AHP," International Journal of Productivity and Quality Management, Inderscience Enterprises Ltd, vol. 23(2), pages 187-217.
    14. S. Mahalakshmi & A. Arokiasamy, 2020. "Productivity and quality enrichment through multi criteria trajectory optimisation of an industrial robot," International Journal of Productivity and Quality Management, Inderscience Enterprises Ltd, vol. 30(3), pages 279-303.
    15. Santosh B. Rane & Milind Shrikant Kirkire, 2016. "Analysis of barriers to medical device development in India: an interpretive structural modelling approach," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 7(3), pages 356-369, September.
    16. Sanjeev Yadav & Sunil Luthra & Dixit Garg, 2022. "Internet of things (IoT) based coordination system in Agri-food supply chain: development of an efficient framework using DEMATEL-ISM," Operations Management Research, Springer, vol. 15(1), pages 1-27, June.
    17. S. Mahalakshmi & A. Arokiasamy & J. Fakrudeen Ali Ahamed, 2019. "Productivity improvement of an eco friendly warehouse using multi objective optimal robot trajectory planning," International Journal of Productivity and Quality Management, Inderscience Enterprises Ltd, vol. 27(3), pages 305-328.
    18. Raju Kamble & Lalit Wankhade, 2017. "Perspectives on productivity: identifying attributes influencing productivity in various industrial sectors," International Journal of Productivity and Quality Management, Inderscience Enterprises Ltd, vol. 22(4), pages 536-566.
    19. Rahmah Ismail, 2018. "The impact of human capital and innovation on labour productivity of Malaysian small and medium enterprises," International Journal of Productivity and Quality Management, Inderscience Enterprises Ltd, vol. 25(2), pages 245-261.
    20. Mexia, Joao Tiago, 1990. "Best linear unbiased estimates, duality of F tests and the Scheffe multiple comparison method in the presence of controlled heteroscedasticity," Computational Statistics & Data Analysis, Elsevier, vol. 10(3), pages 271-281, December.
    21. G. Selvam & S. Arockia Doss Prince & V. Surya Prakash & T. Rohit, 2018. "Quality and productivity improvement through spot welding process optimisation in automobile body shop," International Journal of Productivity and Quality Management, Inderscience Enterprises Ltd, vol. 23(1), pages 110-127.
    22. Chew Keat Cheah & Joshua Prakash & Kok Seng Ong, 2020. "Overall equipment effectiveness: a review and development of an integrated improvement framework," International Journal of Productivity and Quality Management, Inderscience Enterprises Ltd, vol. 30(1), pages 46-71.
    23. Santosh B. Rane & Yahya A.M. Narvel & Niloy Khatua, 2017. "Development of mechanism for mounting secondary isolating contacts (SICs) in air circuit breakers (ACBs) with high operational reliability," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 8(2), pages 1816-1831, November.
    24. Nakamura, Koji & Kaihatsu, Sohei & Yagi, Tomoyuki, 2019. "Productivity improvement and economic growth: lessons from Japan," Economic Analysis and Policy, Elsevier, vol. 62(C), pages 57-79.
    25. Costa, Luana Bonome Message & Godinho Filho, Moacir & Fredendall, Lawrence D. & Devós Ganga, Gilberto Miller, 2021. "Lean six sigma in the food industry: Construct development and measurement validation," International Journal of Production Economics, Elsevier, vol. 231(C).
    26. Sharfuddin Ahmed Khan & M. Affan Badar & Mohammed Alzaabi, 2020. "Productivity improvement using DMAIC in a Caravan Manufacturing company," International Journal of Productivity and Quality Management, Inderscience Enterprises Ltd, vol. 30(2), pages 234-251.
    27. Raj Kumar & Parveen Kalra & Suman Kant, 2020. "Productivity enhancement of assembly line by using Maynard operation sequence technique after identification of lean wastages," International Journal of Productivity and Quality Management, Inderscience Enterprises Ltd, vol. 29(4), pages 463-482.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Mariam Alzeraif & Ali Cheaitou, 2024. "Factors influencing maintenance labor productivity in the electricity industry," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 15(6), pages 2141-2154, June.

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Sainath G. Bidikar & Santosh B. Rane & Prathamesh R. Potdar, 2022. "Product development using Design for Six Sigma approach: case study in switchgear industry," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 13(1), pages 203-230, February.
    2. Santosh B. Rane & Yahya Abdul Majid Narvel, 2022. "Data-driven decision making with Blockchain-IoT integrated architecture: a project resource management agility perspective of industry 4.0," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 13(2), pages 1005-1023, April.
    3. Santosh B. Rane & Yahya A. M. Narvel, 2021. "Leveraging the industry 4.0 technologies for improving agility of project procurement management processes," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 12(6), pages 1146-1172, December.
    4. Santosh B. Rane & Prathamesh R. Potdar & Suraj Rane, 2019. "Accelerated life testing for reliability improvement: a case study on Moulded Case Circuit Breaker (MCCB) mechanism," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 10(6), pages 1668-1690, December.
    5. M. Suresh & G. Mahadevan & R. Dev Abhishek, 2019. "Modelling the factors influencing the service quality in supermarkets," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 10(6), pages 1474-1486, December.
    6. Sandeep Jadhav & Ahmed Imran & Marjia Haque, 2023. "Application of six sigma and the system thinking approach in COVID-19 operation management: a case study of the victorian aged care response centre (VACRC) in Australia," Operations Management Research, Springer, vol. 16(1), pages 531-553, March.
    7. Anastasia Vasileiou & Eleni Sfakianaki & Georgios Tsekouropoulos, 2024. "Exploring Sustainability and Efficiency Improvements in Healthcare: A Qualitative Study," Sustainability, MDPI, vol. 16(19), pages 1-34, September.
    8. Metzker Soares, Paula & Thevenin, Simon & Adulyasak, Yossiri & Dolgui, Alexandre, 2024. "Adaptive robust optimization for lot-sizing under yield uncertainty," European Journal of Operational Research, Elsevier, vol. 313(2), pages 513-526.
    9. Rajiv Kumar Sharma, 2022. "Examining interaction among supplier selection strategies in an outsourcing environment using ISM and fuzzy logic approach," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 13(5), pages 2175-2194, October.
    10. Ichiro Fukunaga & Yoshihiko Hogen & Yoichi Ueno, 2024. "Japan's Economy and Prices over the Past 25 Years: Past Discussions and Recent Issues," Bank of Japan Working Paper Series 24-E-14, Bank of Japan.
    11. Karim Nadim & Ahmed Ragab & Mohamed-Salah Ouali, 2023. "Data-driven dynamic causality analysis of industrial systems using interpretable machine learning and process mining," Journal of Intelligent Manufacturing, Springer, vol. 34(1), pages 57-83, January.
    12. Tomoyuki Yagi & Kakuho Furukawa & Jouchi Nakajima, 2022. "Productivity Trends in Japan - Reviewing Recent Facts and the Prospects for the Post-COVID-19 Era -," Bank of Japan Working Paper Series 22-E-10, Bank of Japan.
    13. Qianhui Ma & Lan Ju & Zishi Zhang, 2022. "Innovation Input and Firm Value: Based on the Moderating Effect of Internal Control," Sustainability, MDPI, vol. 14(18), pages 1-24, September.
    14. Gnangnon, Sèna Kimm, 2020. "Aid for Trade flows and Poverty Reduction in Recipient-Countries," EconStor Preprints 213807, ZBW - Leibniz Information Centre for Economics.
    15. Mehdi Tavakoli & Mehdi Nafar, 2021. "Modification of the FFTA method for calculating and analyzing the human reliability of maintenance groups in power transmission grids," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 12(6), pages 1221-1234, December.
    16. Qin, Hongchuan & Zhang, Bingtao & Zhou, Renjie & Sun, Yating & Tian, Haichuan & Wang, Zichen & Wu, Shijun & Li, Xi & Jiang, Jianhua, 2024. "Efficiency and longevity trade-off analysis and real-time dynamic health state estimation of solid oxide fuel cell system," Applied Energy, Elsevier, vol. 372(C).
    17. Hamed Gholami & Norhazrina Jamil & Muhamad Zameri Mat Saman & Dalia Streimikiene & Safian Sharif & Norhayati Zakuan, 2021. "The application of Green Lean Six Sigma," Business Strategy and the Environment, Wiley Blackwell, vol. 30(4), pages 1913-1931, May.
    18. Xiaowei Fu & Yanlin Liu & Xi Li, 2020. "Source Diagnosis of Solid Oxide Fuel Cell System Oscillation Based on Data Driven," Energies, MDPI, vol. 13(16), pages 1-13, August.
    19. Xiaohan Li & Chenwei Ma & Yang Lv, 2022. "Environmental Cost Control of Manufacturing Enterprises via Machine Learning under Data Warehouse," Sustainability, MDPI, vol. 14(18), pages 1-21, September.
    20. Hiroki, Takashi & Iwatsubo, Kentaro & Watkins, Clinton, 2022. "Does firm-level productivity predict stock returns?," Pacific-Basin Finance Journal, Elsevier, vol. 72(C).

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:spr:ijsaem:v:14:y:2023:i:5:d:10.1007_s13198-023-01980-7. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Sonal Shukla or Springer Nature Abstracting and Indexing (email available below). General contact details of provider: http://www.springer.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.