Implementation of Additive Manufacturing and Lean Six Sigma Methodologies in an Advertising Company

Cira Blanco, Gloria Cecilia
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Application of Lean Six Sigma concepts and tools is known to have improved the efficiency of processes by removing non-value adding activities which are considered as operational wastes in a company. Additive Manufacturing (AM) has become a revolutionary tool that complements the Lean Six Sigma ideology by further reducing the cost of arbitrary processes. This thesis research focuses on the analysis of the total part cost of a fully automated sorting system in an advertising company. The Six Sigma methodology known as "Define, Measure, Analysis, Improvement, and Control" (DMAIC), was used throughout the study process to identify what was causing the inadvertent production costs and the possible solutions with the use of AM. Throughout the process, it was found that the use of an outsourced part of the sorting system increases cost and incurs unexpected delays with an estimate of $36,000 annual costs. Savings up to 80% of this annual cost can be achieved by making this part in-house using AM technology and our methodology. Several prototypes of this part went through an empirical test to determine their reliability level in terms of efficiency and cost-effectiveness. The results showed that Nylon proved to be an efficient candidate material due to its versatility and durability properties, making it capable to sustain the same workload as the part made from the original material with significantly less cost.

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Additive manufacturing, DMAIC, Define, Measure, Analysis, Improvement, and Control, Lean Six Sigma
Mechanical Engineering