Reducing Defects in CAF Enterprises (Stonecast) Manufacturing at Lapu-Lapu City Using a Lean Six Sigma Approach

This study explores the application of Lean Six Sigma (LSS) methodologies to reduce defects in the manufacturing processes of CAF Enterprises (Stonecast) in Lapu-Lapu City, Philippines. The research focuses on addressing five critical defects—cracks, pits, surface irregularities, dimensional inaccuracies, and incomplete curing—that negatively impact product quality and operational efficiency. Utilizing the DMAIC (Define, Measure, Analyze, Improve, Control) framework, data was collected from June to September 2023 to identify root causes and evaluate the manufacturing process. Analytical tools, including Pareto Charts, Fishbone Diagrams, Failure Modes and Effects Analysis (FMEA), and 5W1H were employed to diagnose and prioritize issues for intervention. The study implemented process optimization strategies and standardized work instructions to minimize defect rates, resulting in notable quality improvements. By reducing waste, enhancing production consistency, and promoting resource efficiency, the study contributes to Sustainable Development Goal (SDG) 9: Industry, Innovation, and Infrastructure by fostering technological advancement and operational excellence in manufacturing. Additionally, aligning with SDG 12: Responsible Consumption and Production, this research supports sustainable production practices by minimizing material waste and improving efficiency. The findings demonstrate the effectiveness of LSS methodologies in achieving defect reduction, waste minimization, and sustainable industrial growth, offering valuable insights for similar manufacturing environments aiming for continuous improvement and sustainability. similar manufacturing environments aiming to improve product quality and efficiency.