Using Lean Six Sigma to Improvement the Productivity of the Mark, Scan and Pack Process in the Semiconductor Industry

抄録

Increasing the organisation's productivity can directly affect operational and financial performance and is regarded as a crucial tactic for achieving industrial excellence. Productivity is a fundamental metric that affects work-in-progress inventory, production, process utilisation, product cost, and on-time delivery. Hence, engineers and managers are under a lot of pressure to improve organisational performance. The Man-to-Machine-Ratio (MMR) was changed from 1:1 to 2:1 to improve machine coverage and increase the Mark, Scan, and Pack (MSP) process performance for product line X. However, this modification has resulted in a lower productivity output of only 4,000 pieces per man-hour compared to the management objectives of 6,000 pieces per man-hour. In this study, the researchers have concentrated on increasing the Personnel Efficiency (PE) at the MSP process while identifying Non-Value-Added (NVA) activities. To increase productivity, the researchers used the Define, Measure, Analyse, Improve, and Control (DMAIC) technique of the Lean Six Sigma process. A detailed examination of work procedures, motion, and time was carried out to classify jobs as Value-Added (VA) or NVA using work study tools and Kaizen worksheets. The results showed an increase in production from 4000 to 6000 pieces per man-hour by reducing labour steps and improving the MMR from 2:1 to 1:1. The study's findings demonstrate that lean Kaizen techniques and work element analysis have been successfully used to enhance PE and productivity in manufacturing operations.