Lean Implementation Framework: A Case of Performance Improvement of Casting Process

Globalization breeds increasing competition. In today’s dynamic climate, lean thinking has been found a promising business continuous improvement strategy for improving quality while reducing product cost and delivery time. However, its implementation nature of challenges that varies from industry to country country, necessitating specific framework by taking all stakeholders onboard. This study aims propose reduce defects waste improve the performance metal casting industry. The structure divided into three phases namely conception phase, sustainability phase. proposed integrates six sigma DMAIC methodology with tools techniques achieve improvement. A solid cast software used as computer-assisted simulation tool perform analysis within casting. Further, is demonstrated validated employing real-time case was manufactured using sand process. obtained results show remarkable improvements in poured weight (33.3%), mold including gating system (40%), yield (24.56%, rejection rate (90%), financial saving (24.63%). As result percentage data, can provide practitioners standard roadmap motivate industries implement through organizational change. Through effective application framework, enhancement demonstrated.