Lean Six Sigma methodology to reduce excess wastage in a brickyard: A case study.
By Quiroz-Flores, J. C., Varas, I. F., & Ali, A.
Quiroz-Flores, J. C., Varas, I. F., & Ali, A. (2023, August). Lean Six Sigma methodology to reduce excess wastage in a brickyard: A case study. South African Journal of Industrial Engineering, 34(2), 205–218.
This scholarly article examines the implementation of the Lean Six Sigma (LSS) methodology within the context of a brick manufacturing facility to address high levels of production waste. Utilizing the DMAIC (Define, Measure, Analyze, Improve, Control) framework, the authors identify the primary causes of defects and material loss during the firing and molding stages. Through the application of statistical tools and Lean techniques, the study demonstrates a significant reduction in waste and a corresponding increase in operational efficiency. The research highlights the challenges of applying sophisticated quality management tools in traditional industrial settings and provides empirical evidence of the financial benefits associated with LSS. The findings suggest that the integration of Lean’s waste reduction and Six Sigma’s variance reduction is highly effective for improving productivity in the construction materials sector. This case study serves as a practical model for practitioners in similar manufacturing environments.