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358163

The impact of integrating LSS and BPR on manufacturing organizational performance

Article

Last updated: 28 Dec 2024

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Tags

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Abstract

Every organization aims to achieve customer satisfaction by delivering high-quality products at a reasonable cost. This research investigates the integration of Lean Six Sigma (LSS) and Business Process Reengineering (BPR) through the DMAIC methodology to enhance the operational performance of manufacturing organizations. The study develops a comprehensive LSS-BPR framework for the manufacturing domain, employing various analysis and improvement tools within the DMAIC methodology. The framework is applied specifically to the production of electrical control panels in Egypt. The implementation results in significant improvements, including a reduction in panel shop drawings cycle time from 3 hours to 2 hours, a decrease in panel lead time from 3.9 days to 1.07 days, an increase in annual panels production from 1986 panels to 4056 panels, a rise in the sigma level from 2.45 sigma to 3.37 sigma, and a decrease in the defect ratio from 17.1% to 3.1%. Additionally, customer complaints decrease substantially from 45 to only 3 throughout the year. The study recommends extending this methodology for application across diverse production processes in various organizations.

DOI

10.21608/esju.2024.246070.1021

Keywords

Lean Six Sigma, Business Process Reengineering, DMAIC, continuous improvement, Manufacturing

Authors

First Name

Somaia

Last Name

Gomaa

MiddleName

-

Affiliation

Cairo university

Email

somaiagomaa@gmail.com

City

6 October

Orcid

-

First Name

Mohamed

Last Name

Fahmy

MiddleName

-

Affiliation

Faculty of Engineering, Fayoum University.

Email

mfa03@fayoum.edu.eg

City

-

Orcid

-

First Name

Eman

Last Name

Mosallam

MiddleName

-

Affiliation

General coordinator of Graduate Studies for statistical research, Faculty of Graduate Studies for Statistical Research, Cairo University

Email

emanmosallam@gmail.com

City

-

Orcid

-

Volume

68

Article Issue

1

Related Issue

46950

Issue Date

2024-06-01

Receive Date

2023-12-04

Publish Date

2024-06-03

Page Start

45

Page End

58

Print ISSN

0542-1748

Online ISSN

2786-0086

Link

https://esju.journals.ekb.eg/article_358163.html

Detail API

https://esju.journals.ekb.eg/service?article_code=358163

Order

4

Type

Original Article

Type Code

1,914

Publication Type

Journal

Publication Title

The Egyptian Statistical Journal

Publication Link

https://esju.journals.ekb.eg/

MainTitle

The impact of integrating LSS and BPR on manufacturing organizational performance

Details

Type

Article

Created At

28 Dec 2024