Integration Of Lean, Green And Six Sigma Principles To Reduce Materials Waste

Abstract

When Implemented Individually, Lean, Green And Six Sigma Initiatives Are Very Successful In Materials Waste Reduction. However, Many Reviewed Literatures Reveal That, The Integration And Simultaneous Implementation Of These Paradigms Improves The Performances Of Organizations More. Green, Lean And Six Sigma Are Three Strategies That Are Compatible And Complementary; Thus, Each Strategy Has The Capacity To Reduce The Shortcomings Of The Others. For Instance, Lean Manufacturing Deals With Elimination Of Process Wastes And Non-Value Adding Activities But, Does Not Cover All Environmental Aspects Which Needs The Addition Of Green Manufacturing. Also, Evidences Indicate That The Integration Of The Two Strategies May Have Inherited The Same Limitations As The Individual Green And Lean Approaches, But These May Be Overcame Through The Integration Of Six Sigma. The Purpose Of This Study Was To Present A Model That Converges Lean, Green And Six Sigma Principles As A Tool To Reduce Solid Materials Waste. A Case Study Was Conducted On Adama Agricultural Machinery Industry And Qualitative Research Approach Was Employed To Study The Gap Between Theoretical Concepts And Real Company Case. Survey Of Related Works, Informal Interviews, Physical Observations, And Focus Group Discussions Were Used To Collect Data. Waste Materials Currently Exist In The Company Were Documented And Categorized As Surplus, Obsolete And Scrap. The Root Causes Of Each Waste Category Were Identified, Prioritized And Correction Actions Were Recommended. The Results From Fmea Indicates That, Rpn Of 80, 63 And 18 Were Obtained For Surplus, Obsolete And Scrap Materials Waste Respectively. Surplus Waste Category Is Most Severe And Needs Immediate Action. Finally, A Model That Converges The Lean, Green And Six Sigma Principles Was Developed As A Tool Of Materials Waste Reduction. The Model Requires Motivation And Awareness Of Employees On Lgss Principles Before Implementation And Needs To Be Sustained If Implemented Once. Since The Company Did Not Adopted None Of Paradigms It May Take A Long Time To Implement The Model At A Maturity Level. However, It Will Be Possible Through The Application Of Critical Success Factors. This Model May Bring A Tangible Improvements To A Waste Minimization Program And It Can Be A Part Of Options For Aami As Well As Other Organizations Seeking To Achieve Sustainability, If They Will Implement It.