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

Garza-Reyes, Jose Arturo; Al-Balushi, Mustafa; Antony, Jiju; Kumar, Vikas

Abstract

© 2016 Informa UK Limited, trading as Taylor & Francis Group. Abstract: Evidence suggests that specifically designed frameworks to implement Lean Six Sigma (LSS) projects to tackle particular problems are more effective than ‘generic’ versions. This paper proposes an implementation framework to effectively deploy LSS to improve a key operation and performance indicator, i.e. ship loading commercial time, of one of the largest world producer of iron ore. This article therefore contributes with a refined framework to effectively implement LSS, and documents its successful application and effectiveness within the context of the case organisation. The LSS framework and project contributed in helping the studied organisation to improve both the capability of its ship loading process and commercial time by more than 30%, resulting in operational savings in the range of $300,000 USD per year. The systematic nature of the framework proposed also helped the organisation to establish a standardised routine to improve its operations. Managerial implications exposing the challenges faced during the implementation of LSS are also discussed to serve as lessons learnt to be considered in other LSS projects. Managers and engineers incharge of improving operations and processes can benefit from this paper as it can be used as a guide to direct the conduction of LSS projects and the empirical application of its principles and tools.

• Journal Article Type: Article
• Acceptance Date: Apr 28, 2016
• Online Publication Date: May 15, 2016
• Publication Date: May 15, 2016
• Deposit Date: Apr 26, 2016
• Publicly Available Date: May 15, 2017
• Journal: Production Planning and Control
• Print ISSN: 0953-7287
• Electronic ISSN: 1366-5871
• Publisher: Taylor & Francis
• Peer Reviewed: Peer Reviewed
• Volume: 27
• Issue: 13
• Pages: 1092-1111
• DOI: https://doi.org/10.1080/09537287.2016.1185188
• Keywords: DMAIC, iron ore industry, lean, lean six sigma, operations improvement, six sigma
• Public URL: https://uwe-repository.worktribe.com/output/911976
• Publisher URL: http://dx.doi.org/10.1080/09537287.2016.1185188
• Additional Information: Additional Information : This is an Accepted Manuscript of an article published by Taylor & Francis in Production Planning & Control on 15 May 2016, available online: http://www.tandfonline.com/10.1080/09537287.2016.1185188.
• Contract Date: Apr 26, 2016