International Journal of Science and Research (IJSR) ISSN (Online): 2319-7064 Index Copernicus Value (2015): 78.96 | Impact Factor (2015): 6.391 Volume 6 Issue 6, June 2017 www.ijsr.net Licensed Under Creative Commons Attribution CC BY Productivity Improvement through Lean, Green and Six Sigma Techniques M Yogesh 1 , Dr M T Simon 2 Associate Professor & Head, Aeronautical Department, Mount Zion College of Engineering, Kadammanitta, Pathanamthitta, Kerala, India. Dean, Mount Zion College of Engineering, Kadammanitta, Pathanamthitta, Kerala, India Abstract: The barriers blocking the effectiveness in lean tools implementation to SME’s (Small & Medium Enterprises) in India are found from a case study. For increasing the productivity and efficiency, an integrated form of lean, green and six sigma techniques are suggested. Since SMEs in India form the back bone of economic growth, the productivity and efficiency are to be tuned up for sustained and continual improvement, quality of product is maintained steadily. This can be done by lean-six sigma techniques. A healthy environment has to be maintained hence a green technology is adopted. By an integrated form of lean, green six sigma techniques, products are manufactured at minimum cost, quality is maintained and manufacturing techniques are adopted so as to have minimum environmental damage. Priority is given to the needs and requirement of the customer so as to survive the global competition. Keywords: Lean technology, Wastes, Green technology, Environmental Pollution, Six Sigma, SMEs. 1. Introduction TOWARDS the dawn of twenty first century, as a result of tight global competition, SMEs in India could not sustain a steady increase in productivity and efficiency of its performance. By this time, most of the large scale industries implemented lean tools, six sigma techniques and they have achieved tremendous increase in productivity. But in fact SMEs play a key role in the growth of Indian economy contributing to 45% of industrial output, 40% of exports and 1.3 million jobs per year. So SMEs form the backbone of Indian economy. Most of the SMEs in India started implementing lean tools and complementary tools like TQM, Six Sigma methodologies to improve their performance in early 2005. But in the initial period, these industrial concerns have not shown appreciable growth in their economy and productivity. At this context we made a thorough study on the effectiveness of implementation of lean tools and related techniques [1]. Our study focused on the following aspects: (1) The extent of awareness regarding lean tools, TQM, Six Sigma techniques giving ample stress on maintaining a healthy environment. (2) Measures to educate the management executive and workmen regarding Lean tools, Six Sigma techniques, TQM and environment friendly measures. (3) Effective implementation of rational integrated version of Lean, Green Six Sigma techniques (4) Measurement of performance indicators namely productivity, profit margin, TEEP (Total Effective Equipment Productivity) and OEE (Overall Equipment Efficiency). If performance indicators do not attain the target aimed at, measures are taken to implement the tools effectively. We suggest a six step process for effective implementation. The different steps are the following: a) Identification of the problem or barrier blocking the productivity of performance. b) Analyzing the nature of the problem. c) Finding out the exact cause of not attaining the required level of increase in productivity. d) Remedial measures for rectifying it. e) Evaluating the productivity and quality factor attained on implementation of remedial measures. f) Ascertain whether required level of increase of productivity has attained by the remedial measures. If not repeat the process until the required level of increase in productivity has attained. For our study on evolving an effective integrated approach of lean, green and six sigma techniques [2] of attaining manufacturing excellence with continuous process improvement meeting the customer specific requirements. For the work, we have selected an Electronic manufacturing unit. We received liberal support from the management for our study and allowed us to collect data from its record. The company has 770 employees and the manufacturing division of the company has presently 648 workers in two shifts, belonging to four different manufacturing sections namely plating section with 60 workers, molding section with 60 workers, stamping section with 48 workers and assembly section with 480 workers. It has an average turnover of 400 crores with a profit margin of 240 crores. The aim of the company is to become the benchmark in the electronics manufacturing market. The company has received quality performance awards in recognition of achievement of excellent quality and zero customer complaints. The company record shows that turnover of the company has been steadily increasing until 2005 and as a result of globalization; it has to face a severe competition. To tone up the productivity and efficiency of manufacturing, the company started implementing lean tools. Lean tools were applied to each of the four departments of manufacturing Paper ID: ART20174197 406