Success Story Assessment Of Lean Six Sigma Implementation And Development Of Conceptual Framework For Beer George Industry: Ethiopia Brewery Company

Abstract

Lean Six-Sigma Methodology Is Becoming Very Powerful Improvement Methodology In 21st Century. More Than 2100 Studies Were Carried Out Regarding The Implementation Of The Methodology On Process Industries Since The Beginning In 2000. Especially In Developed Countries Like United Kingdom, United States Of America And Other Countries. This Methodology Also Implemented In Some Developing Countries Including African Countries Such As Nigeria, Uganda, Egypt, South Africa And Others But It Is In Its Binging Stage. In Addition, The Study Related To Implementation Of Lean Six-Sigma Methodology For Food Processing Industries Were Very Few Including Beverage Industries Because Implementation On Food Process Started Lately And There Is No Specific Framework Developed. And Also, There Is No Evidence That Shows The Implementation Of This Integrated Manufacturing Methodology In Ethiopian Industries. Hence, The Purpose Of This Study Is To Assess The Success Story Of Lean Six-Sigma Implementation In Different Industries Around The Globe Through Literature Review And Identifying The Existing Gaps And, Develop Conceptual Framework For Ethiopia Beer George Bottling Line Process. Literature Review Was Categories In Three (Literature On Lean, On Six-Sigma And Lean Six-Sigma) Based On Title, Abstract, Keyword And Conclusion And Relevant Papers Were Selected Based On The Year Of Publication, Area Of Study And Success Story Of Implementation. Data Has Collected Through Interview, Observation And Measurement From Both Primary And Secondary Data Sources And Analyzed Using Qualitative And Quantitative Analysis Methods Including Different Lean And Six-Sigma Tools Like, Supply Input Process Output Control Diagram, Value Stream Mapping And Pareto Chart With The Help Of Sigma-Xl V8 Software. As A Result, The Bottling Line Showed 8 Different Wastes And 74439 Defected Bottles Per Million Which Indicates The Sigma Level Of The Process Is 2.944 Sigma, 74% Of The Operation Time Is Value Added Time And 66 Minutes Of The Lead Time Is None Value Added Time. In Addition To That Some Critical Success Factors That Will Help For Successful Implementation Such As Communication, Employee Involvement And Employee Motivation And Challenges That Affects The Production Process Such As Bureaucracy In Company Process And Shortage Of Green Currency/Dollar Were Identified During Study In The Company. Proper Implementation Of The Framework Will Improve The Quality Of The Product And Will Increase Production Capacity Of The Process By Reducing Defects And By Eliminating Wastes Found On The Bottling Line. V Based On The Finding, A Conceptual Lean Six-Sigma Framework Was Developed For St. George Beer Bottling Line Process Of Beer George Industry Ethiopia Brewery Company. During Development Of Framework Define-Measure-Analyze-Improve-Control Approach Is Used As Base Line And Integrated With Each Other In All Phases. Implementation And Validation Of The Framework Will Conduct In Future.