Applying the DMAIC Framework to Improve Productivity and Quality in the Latex Mattress Production Process

This study applies the DMAIC model with the support of tools such as Product family, Flow chart, seven types of waste, fishbone diagram, Pareto chart, 5S, visual management, SOP, FMEA, etc., to identify, evaluate, and analyze the root causes of waste, quality defects as well as unreasonable points in the latex mattress production process, thereby providing innovative solutions to minimize waste, improve quality and labor efficiency of workers. The root causes of the primary defects and some wastes, such as waiting for waste, transportation waste, and operational waste, were defined. This thereby provides appropriate solutions and improvements to reduce rising waste, enhance worker productivity, and improve production processes and product quality. Standard operating procedures are established to guide and maintain work quality while helping workers avoid mistakes. Some achievements are as follows: Chemical transportation time was reduced by 72%; time to pick up semi-finished products for rolling, washing, and drying stages was reduced by 61%; customer feedback rate on plastic packaging defect was also reduced.