Publication Cover
Production Planning & Control
The Management of Operations
Volume 27, 2016 - Issue 13
849
Views
50
CrossRef citations to date
0
Altmetric
Original Articles

A Lean Six Sigma framework for the reduction of ship loading commercial time in the iron ore pelletising industry

, , &
Pages 1092-1111 | Received 03 Feb 2016, Accepted 28 Apr 2016, Published online: 15 May 2016

References

  • Achanga, P., E. Shehab, R. Roy, and G. Nelder. 2006. “Critical Success Factors for Lean Implementation within SMEs.” Journal of Manufacturing Technology Management 17 (4): 460–471.
  • Anand, G., P. T. Ward, and M. V. Tatikonda. 2010. “Role of Explicit and Tacit Knowledge in Six Sigma Projects: An Empirical Examination of Differential Project Success.” Journal of Operations Management 28 (4): 303–315.10.1016/j.jom.2009.10.003
  • Antony, J., F. E. Antony, M. Kumar, and B. R. Cho. 2007. “Six Sigma in Service Organisations: Benefits, Challenges and Difficulties, Common Myths, Empirical Observations and Success Factors.” International Journal of Quality & Reliability Management 24 (3): 294–311.
  • Antony, J., M. Kumar, and M. Tiwari. 2005. “An Application of Six Sigma Methodology to Reduce the Engine-overheating Problem in an Automotive Company.” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 219 (8): 633–646.10.1243/095440505X32418
  • Baker, T., and V. Jayaraman. 2012. “Managing Information and Supplies Inventory Operations in a Manufacturing Environment. Part 1: An Action Research Study.” International Journal of Production Research 50 (6): 1666–1681.10.1080/00207543.2010.550697
  • Basu, R. 2009. Implementing Six Sigma and Lean. Oxford: Butterworth-Heinemann.
  • Bicheno, J. 2004. The New Lean Toolbox: Towards Fast, Flexible Flow. 3rd ed. Buckingham: PICSIE Books.
  • Bortolotti, T., S. Boscari, and P. Danese. 2015. “Successful Lean Implementation: Organizational Culture and Soft Lean Practices.” International Journal of Production Economics 160: 182–201.10.1016/j.ijpe.2014.10.013
  • Bouslah, B., A. Gharbi, and R. Pellerin. 2016. “Joint Economic Design of Production, Continuous Sampling Inspection and Preventive Maintenance of a Deteriorating Production System.” International Journal of Production Economics 173: 184–198.10.1016/j.ijpe.2015.12.016
  • Breyfogle III, F. W. 2008. “Better Fostering Innovation: 9 Steps that Improve Lean Six Sigma.” Business Performance Management Magazine 6 (3): 16–20.
  • Brue, G. 2002. Six Sigma for Managers. New York, NY: McGraw-Hill.
  • Bryman, A. 1989. Research Methods and Organization Studies. London: Unwin Hyman.10.4324/9780203359648
  • Cagliano, R., F. Caniato, M. Corso, and G. Spina. 2005. “Collaborative Improvement in the Extended Manufacturing Enterprise: Lessons from an Action Research Process.” Production, Planning & Control 16 (4): 345–355.
  • Chakrabarty, A., and K. C. Tan. 2007. “The Current State of Six Sigma Application in Services.” Managing Service Quality: An International Journal 17 (2): 194–208.10.1108/09604520710735191
  • Chen, M. N., and J. J. Lyu. 2009. “A Lean Six-Sigma Approach to Touch Panel Quality Improvement.” Production, Planning & Control 20 (5): 445–454.
  • Chinbat, U., and S. Takakuwa. (2008), “Using Operation Process Simulation for a Six Sigma Project of Mining and Iron Production Factory.” Proceedings of the Winter Simulation Conference (WSC), Austin, TX, December 7–10, 2431–2438.
  • Coughlan, P., and D. Coghlan. 2002. “Action Research for Operations Management.” International Journal of Operations and Production Management 22 (2): 220–240.10.1108/01443570210417515
  • Cudney, E. A., S. Furterer, and D. Dietrich, eds. 2013. Lean Systems: Applications and Case Studies in Manufacturing, Service, and Healthcare. Boca Raton, FL: CRC Press.
  • Deshmukh, S. V., and R. R. Lakhe. 2009. “An Innovation Model of Six Sigma for SMEs: The T-DMAIC Model.” International Journal of Six Sigma and Competitive Advantage 5 (2): 187–203.10.1504/IJSSCA.2009.025169
  • Dey, P. K., A. Bhattacharya, and W. Ho. 2015. “Strategic Supplier Performance Evaluation: A Case-based Action Research of a UK Manufacturing Organisation.” International Journal of Production Economics 166: 192–214.10.1016/j.ijpe.2014.09.021
  • Farooq, S., and C. O’Brien. 2015. “An Action Research Methodology for Manufacturing Technology Selection: A Supply Chain Perspective.” Production, Planning & Control 26 (6): 467–488.
  • Fortune, J. 1992. “Idea Generation Techniques for Quality Improvement.” International Journal of Quality and Reliability Management 9 (6): 32–38.
  • Furterer, S. L. 2009. Lean Six Sigma in Service. Boca Raton, FL: CRC Press.10.1201/9781420079104
  • Garza-Reyes, J. A., A. Flint, V. Kumar, J. Antony, and H. Soriano-Meier. 2014. “A DMAIRC Approach to Lead Time Reduction in an Aerospace Engine Assembly Process.” Journal of Manufacturing Technology Management 25 (1): 27–48.10.1108/JMTM-05-2012-0058
  • Garza-Reyes, J. A., I. Oraifige, H. Soriano-Meier, D. Harmanto, and L. Rocha-Lona. 2010. “An Empirical Application of Six Sigma and DMAIC Methodology for Business Process Improvement.” Proceedings of the 20th International Conference on Flexible Automation and Intelligent Manufacturing (FAIM), San Francisco, CA, US, July 12–14.
  • Ghosh, S., and J. Maiti. 2014. “Data Mining Driven DMAIC Framework for Improving Foundry Quality – A Case Study.” Production, Planning & Control 26 (6): 478–493.
  • Gonçalves, F., C. Bezerra, A. Belchior, C. Coelho, and C. Pires. 2008. “Implementing Causal Analysis and Resolution in Software Development Projects: The MiniDMAIC Approach.” Proceedings of the 19th Australian Conference on Software Engineering, Washington, DC, 112–119.
  • Gowen, C. R. III, G. N. Stock, and K. L. Mcfadden. 2008. “Simultaneous Implementation of Six Sigma and Knowledge Management in Hospitals.” International Journal of Production Research 46 (23): 6781–6795.10.1080/00207540802496162
  • Gutierrez, D. M., L. F. Scavarda, L. Fiorencio, and R. A. Martins. 2015. “Evolution of the Performance Measurement System in the Logistics Department of a Broadcasting Company: An Action Research.” International Journal of Production Economics 160: 1–12.10.1016/j.ijpe.2014.08.012
  • Harry, M. J., P. S. Mann, O. C. de Hodgins, R. L. Hulbert, and J. C. Lacke. 2010. Practitioners Guide to Statistics and Lean Six Sigma for Process Improvement. Hoboken, NJ: Wiley.
  • Hicks, C., T. McGovern, G. Prior, and I. Smith. 2015. “Applying Lean Principles to the Design of Healthcare Facilities.” International Journal of Production Economics 170: 677–686.10.1016/j.ijpe.2015.05.029
  • Hines, P., M. Holweg, and N. Rich. 2004. “Learning to Evolve: A Review of Contemporary Lean Thinking.” International Journal of Operations and Production Management 24 (10): 994–1011.10.1108/01443570410558049
  • Hokoma, R. A., M. K. Khan, and K. Hussain. 2010. “The Present Status of Quality and Manufacturing Management Techniques and Philosophies within the Libyan Iron and Steel Industry.” The TQM Journal 22 (2): 209–221.10.1108/17542731011024309
  • Implementation Engineers. 2016. “Operational Excellence in Iron Ore Mining.” Accessed April 3, 2016. http://implementation.com/our-expertise/case-studies/d/operational-excellence-in-iron-ore-mining
  • IndexMundi. 2015. “Iron Ore Monthly Price – US Dollars per Dry Metric Ton.” Accessed April 15, 2015. http://www.indexmundi.com/commodities/?commodity=iron-ore&months=12
  • Indrawati, S., and M. Ridwansyah. 2015. “Manufacturing Continuous Improvement Using Lean Six Sigma: An Iron Ores Industry Case Application.” Procedia Manufacturing 4: 528–534.10.1016/j.promfg.2015.11.072
  • Jacobsen, J. 2016. “Cutting Iron Ore Pellet Production Costs via Improved Efficiency Saves Mining Company $8M.” American Society for Quality (ASQ). Accessed April 3, 2016. http://asq.org/knowledge-center/case-studies-production-cost-efficiency-mining.html
  • Jarrar, Y., and A. Neely. 2005. “Six Sigma – Friend or Foe?” Accessed January 11, 2016. http://sixsigma.pbworks.com/f/Six%20Sigma-friend%20or%20foe.pdf
  • Jirasukprasert, P., J. A. Garza-Reyes, V. Kumar, and M. K. Lim. 2014. “A Six Sigma and DMAIC Application for the Reduction of Defects in a Rubber Gloves Manufacturing Process.” International Journal of Lean Six Sigma 5 (1): 2–21.10.1108/IJLSS-03-2013-0020
  • Krueger, D. C., M. M. Parast, and S. Adam. 2014. “Six Sigma Implementation: A Qualitative Case Study Using Grounded Theory.” Production, Planning & Control 25 (10): 873–889.
  • Kumar, M., J. Antony, R. K. Singh, M. K. Tiwari, and D. Perry. 2006. “Implementing the Lean Sigma Framework in an Indian SME: A Case Study.” Production, Planning & Control 17 (4): 407–423.
  • Kumar, S., A. D. Wolfe, and K. A. Wolfe. 2008. “Using Six Sigma DMAIC to Improve Credit Initiation Process in a Financial Services Operation.” International Journal of Productivity and Performance Management 57 (8): 659–676.10.1108/17410400810916071
  • Liker, J. 2004. The Toyota Way: 14 Management Principles Form the World’s Greatest Manufacturer. New York: CWL Publishing Enterprises.
  • de Mast, J. 2004. “A Methodological Comparison of Three Strategies for Quality Improvement.” International Journal of Quality & Reliability Management 21 (2): 198–213.
  • de Mast, J., and J. Lokkerbol. 2012. “An Analysis of the Six Sigma DMAIC Method from the Perspective of Problem Solving.” International Journal of Production Economics 139: 604–614.10.1016/j.ijpe.2012.05.035
  • McCutcheon, D., and J. Meredith. 1993. “Conducting Case Study Research in Operations Management.” Journal of Operations Management 11 (3): 239–256.10.1016/0272-6963(93)90002-7
  • Monden, Y. 1998. Toyota Production System: An Integrated Approach to Just-in-time. 2nd ed. London: Chapman & Hall.
  • Osborne, J. W. 2010. “Improving Your Data Transformations: Applying the Box-Cox Transformation.” Practical Assessment, Research & Evaluation 15 (12): 1–9.
  • Paloma Consulting. 2016. “Case Study 7 – Developing Lean Sigma Skills in KSE’s Iron & Steel Industry”. Accessed April 3, 2016. http://www.palomaconsulting.com/case-studies/manufacturing-and-engineering/case-study-7-developing-lean-sigma-skills-in-kses-iron-steel-industry/
  • Pyzdek, T., and P. A. Keller. 2014. The Six Sigma Handbook; a Complete Guide for Green Belts, Black Belts, and Managers at All Levels. 4th ed. New York: McGraw-Hill Education.
  • Rocha-Lona, L., J. A. Garza-Reyes, and V. Kumar. 2013. Building Quality Management Systems: Selecting the Right Methods and Tools. Boca Raton, FL: Productivity Press, CRC Press, Taylor & Francis.
  • Senapati, N. R. 2004. “Quality and Reliability Corner: Six Sigma: Myths and Realities.” International Journal of Quality & Reliability Management 21 (6/7): 683–690.
  • Shadish, W. R., T. D. Cook, and D. T. Campbell. 2002. Experimental and Quasi-experimental Designs for Generalized Causal Inference. Boston, MA: Houghton Mifflin.
  • Shinka Management. 2012. “Rio Tinto on Lean Manufacturing in the Mining Sector”. Accessed January 17, 2016. http://shinkamanagement.com/rio-tinto-lean-management-mining/
  • Sin, A. B., S. Zailani, M. Iranmanesh, and T. Ramayah. 2015. “Structural Equation Modelling on Knowledge Creation in Six Sigma DMAIC Project and Its Impact on Organizational Performance.” International Journal of Production Economics 168: 105–117.
  • Sternberg, H., G. Stefansson, E. Westernberg, R. Boije af Gennas, E. Allenstrom, and M. L. Nauska. 2013. “Applying a Lean Approach to Identify Waste in Motor Carrier Operations.” International Journal of Productivity and Performance Management 62 (1): 47–65.
  • Sunder, V., and J. Antony. 2015. “Six-sigma for Improving Top-box Customer Satisfaction Score for a Banking Call Centre.” Production, Planning & Control 26 (16): 1291–1305.
  • de Treville, S., J. Antonakis, and N. M. Edelson. 2005. “Can Standard Operating Procedures Be Motivating? Reconciling Process Variability Issues and Behavioural Outcomes.” TQM & Business Excellence 16 (2): 231–241.
  • Villarreal, B., J. A. Garza-Reyes, and V. Kumar. Forthcoming-a. “A Lean Thinking and Simulation-based Approach for the Improvement of Routing Operations.” Industrial Management & Data Systems 116 (5).10.1108/IMDS-09-2015-0385
  • Villarreal, B., J. A. Garza-Reyes, and V. Kumar. Forthcoming-b. “Lean Road Transportation – A Systematic Method for the Improvement of Road Transport Operations.” Production, Planning & Control. http://dx.doi.org/10.1080/09537287.2016.1152405.
  • Vinodh, S., S. G. Gautham, and A. Ramiya. 2011. “Implementing Lean Sigma Framework in an Indian Automotive Valves Manufacturing Organisation: A Case Study.” 22 (7): 708–722.
  • Vinodh, S., S. V. Kumar, and K. E. K. Vimal. 2014. “Implementing Lean Sigma in an Indian Rotary Switches Manufacturing Organisation.” Production, Planning & Control 25 (4): 288–302.
  • Voss, C., N. Tsikriktsis, and M. Frohlich. 2002. “Case Research in Operations Management.” International Journal of Operations and Production Management 22 (2): 195–219.10.1108/01443570210414329
  • Ward, S. W., S. R. Poling, and P. Clipp. 2008. “Selecting Successful Six Sigma Projects.” Quality 47 (10): 50–51.
  • Zhang, M., W. Wang, T. N. Goh, and T. He. 2015. “Comprehensive Six Sigma Application: A Case Study.” Production, Planning & Control 26 (3): 219–234.

Reprints and Corporate Permissions

Please note: Selecting permissions does not provide access to the full text of the article, please see our help page How do I view content?

To request a reprint or corporate permissions for this article, please click on the relevant link below:

Academic Permissions

Please note: Selecting permissions does not provide access to the full text of the article, please see our help page How do I view content?

Obtain permissions instantly via Rightslink by clicking on the button below:

If you are unable to obtain permissions via Rightslink, please complete and submit this Permissions form. For more information, please visit our Permissions help page.