Lean Six Sigma Application for Sustainable Production: A Case Study for Margarine Production in Zimbabwe
W.M. Goriwondo1, N. Maunga2
1Eng. William Msekiwa Goriwondo, Department of Industrial and Manufacturing Engineering, National University of Science and Technology (NUST), Bulawayo, Zimbabwe
2Miss Nyasha Maunga., Department of Industrial and Manufacturing Engineering, National University of Science and Technology (NUST), Bulawayo, Zimbabwe.

Manuscript received on October 01, 2012. | Revised Manuscript received on October 05, 2012. | Manuscript published on October 10, 2012. | PP: 87-96 | Volume-1 Issue-5 October 2012. | Retrieval Number: E0302091512 /2012©BEIESP
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© The Authors. Blue Eyes Intelligence Engineering and Sciences Publication (BEIESP). This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)

Abstract: Lean Six Sigma is an integration of two World Class Manufacturing improvement philosophies(Lean Manufacturing and Six Sigma) that help organizations improve their performance and competitiveness. The principles are applied to margarine manufacturing. The Value Stream Mapping tool is used to map the processes and the Six Sigma’s Define, Measure, Analyze, Improve and Control (DMAIC) methodology applied to attain improvements. The Current State Map (CSM) is drawn and using the DMAIC methodology, the Future State Map (FSM) is drawn. The production line ultimately achieves improvements in cycle times and in Value Added time ratio from 39% to 94%. There are envisaged improvements of up to 86% on cycle times for individual processes.
Keywords: Lean Six Sigma, Process Variance, Margarine Production, World Class Manufacturing