A case study for surgical mask production during the COVID-19 pandemic: continuous improvement with Kaizen and 5S applications

Ozgul Sevval Gultekin · Cigdem Uskup

21 citations0/0 files storedInternational Journal of Lean Six Sigma

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Quality and Supply Management Management and Optimization Techniques Management Systems and Quality Improvement

Abstract

Purpose With the emergence of the COVID-19 pandemic, the production shortage of personal protective equipment (PPE), such as surgical masks, has become increasingly significant. It is vital to quickly provide high-quality, hygienic PPE during pandemic periods. This comprehensive case study aims to confirm that Kaizen and 5S applications reduce wastage rates and stoppages, which as a result, created a more efficient and sustainable workplace in a small–mediumenterprise (SME) producing PPE in Turkey. Design/methodology/approach The method for this case is discussed with the help of a flowchart using the DMAIC cycle: D-define, M-measure, A-analyse, I-improve and C-control. Findings The total stoppages due to fishing line, gripper, piston and yarn welding have decreased by approximately 42.4%. As a result of eliminating wasted time and reduced changeovers, a total of 5,502 min have been saved per month. This increased production of approximately 10.55% per month, led to an addition of 506,184 units. Originality/value The use of lean manufacturing (LM), Six Sigma, Lean Six Sigma and continuous improvement methodologies are not common in textile SMEs. Based on the current literature reviewed, to the best of the authors’ knowledge, this is the first comprehensive case study that combines statistical tools, such as hypothesis tests and LM practices, in the production process for a PPE company operating as a textile SME.

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References

2006Critical success factors for lean implementation within SMEs 2014Lean manufacturing: literature review and research issues 2006Similarities and differences between TQM, six sigma and lean 2016The integration of lean manufacturing, Six Sigma and sustainability: A literature review and future research directions for developing a specific model 2014A Review on Lean Manufacturing Implementation Techniques 2008Implementing 5S within a Japanese context: an integrated management system 2013Lean, Six Sigma and Lean Six Sigma: an analysis based on operations strategy 2015Continuous improvement philosophy – literature review and directions

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2023Operational excellence of the steel industry using the Lean Six Sigma approach: a case study 2024Addressing the Kaizen business operations: the role of triple helix actors during COVID-19 outbreak 2023The analysis of critical success factors for successful kaizen implementation during the COVID-19 pandemic: a textile industry case study 2023Improving spare parts (MRO) inventory management policies after COVID-19 pandemic: a Lean Six Sigma 4.0 project

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