Lean-Sigma as a Strategy in Supply Chain Management During the COVID-19 Pandemic Crisis-Lessons Learned

Abstract

The World-Class Manufacturing Systems were tested for their adaptability and flexibility during the COVID-19 outbreak imposing restrictions and disrupting the supply chains. This chapter describes using Lean-Sigma for three case studies addressing the lessons and critical tools for overcoming uncertainty and challenges in a Latin American facility. Case 1 describes actions for expected sales increasing in a home-improvement product processing. The challenge, in this case, was addressed by using the eight wastes of Lean manufacturing. It is also supported with a layout redistribution and 5S, observing improvements in productivity levels and new technologies upgrading the process connectivity to elements of industry 4.0. Case 2 is a medical product; rapid demand and sales increment is the scenario to decide to adopt a dial-processing system with a robotic arm to automate four activities of the process. Adopted actions increase quality levels by 50% and a more significant efficiency in implementations, which reduces costs from 5.33 to 0.9 IEU/pc taking only two weeks for the ROI. Case 3 shows developments on a new health-related product, using DMADV of DFSS and reengineering as critical strategies for increasing the usability of equipment and resources available in the production area, resulting in a quick ROI and the newcomer successfully introduced to the market.