Integration of Lean Six Sigma with Value Stream Mapping and Simulation to increase Productivity in a Gelatinized Maca Production Plant: A Case Study

Abstract

The DMAIC (define-measure-analyze-improve- control) method of Lean Six Sigma is one of the most widely used because it allows the development of initiatives aimed at quality and continuous improvement in all types of manufacturing companies. The objective of this research is to design a model based on the integration of Lean Six Sigma (DMAIC) with Value Stream Mapping (VSM) and simulation to increase productivity in a gelatinized maca production company. The methodology of this research follows the sequence of the DMAIC method with the integration of VSM based on the production process of gelatinized maca and then simulate it in FlexSim software. The results obtained in the research show that there is a significant improvement in productivity of an additional 5.18% at the time of the simulation, since the production increased from 270 to 284 bags of 200 grams of gelatinized maca and this would lead to a reduction in the amount of material discarded in the activity of sorting maca.