A Proposed Lean Six Sigma-Based Approach for Prioritizing the Impactful Improvement Areas: The Packaging Industry

Abstract This study aims to introduce and evaluate the Waste, Technical Characteristics, and Root Causes of Failure modes (WCFM) approach, a methodology grounded in Lean and Six Sigma principles, for enhancing operational efficiency and product quality in modern manufacturing systems. The purpose of this work is to develop a structured prioritization framework that focuses specifically on areas of improvement with the highest potential impact, effectively steering packaging manufacturing industry toward the most critical elements that mitigate failure modes causes, minimize waste, and elevate customer satisfaction. The WCFM approach is presented as a systematic framework comprising three core components: managing non-value adding elements (waste), optimizing technical characteristics, and analyzing root causes of failure modes. Lean methodologies and Six Sigma principles are integrated, leveraging tools such as Quality Function Deployment (QFD), identification of the eight wastes, and thorough root cause assessments. A case study at an International Company, a food packaging industry, illustrates the application and effectiveness of the WCFM approach in both product and process enhancement. The results of the case study demonstrate a significant 11.85% increase in the availability of key machinery, attributed to strategic interventions guided by the WCFM approach. This improvement indicates enhanced operational efficiency and performance. Practically, the WCFM approach offers a comprehensive strategy for addressing root causes, improving technical characteristics, and minimizing waste in manufacturing processes. By adopting this approach, organizations can enhance overall quality, fortify systems against disruptions, and drive operational efficiency. Additionally, the integration of Total Productive Maintenance (TPM) is highlighted as pivotal in ensuring consistent machinery performance. This study contributes to the field by presenting the WCFM approach as an innovative methodology that combines Lean and Six Sigma principles to address contemporary challenges in manufacturing systems. The integration of various tools and the emphasis on holistic improvement underscore the originality and value of this approach in transforming manufacturing processes.