The global toys market size reached USD 113.9 Billion in 2024.* We’ll look at Lean and  Six Sigma applications in toy manufacturing and finish with a video of how toy figurines are made.

*Source

Six Sigma Used to Achieve Quality Improvement in Toy Manufacturing

In a paper titled “Quality Improvement in Plastic Based Toy Manufacturer Using Six Sigma Method “ authors  Rahmat Nurcahyo, Lukito Rini and Dendi P. Ishak discuss the use of Six Sigma DMAIC methodology to improve quality in a  plastic based toy.

The paper includes:

  • Toy Components
  • Plastic Based Toy Production Process
  • Pareto Chart of Defect Contributors
  • Defect Type Weightings
  • Cause and Effect Diagram
  • FMEA

NOTE: Figures and Charts are in Indonesian. The accompanying explanations are in English.

Click on the following link to read the paper.

FMEA Applied to Toy Production

In a paper titled “Production: A Case Study of Plastic Block Manufacturing Using Pareto-Lorenz and FMEA Methods” authors Marta Jagusiak-Kocik and Justyna Żywiołek present a comprehensive risk assessment and analysis in the production of plastic toys - specifically building blocks.

The paper includes:

  • The Structure of Nonconformities of Toys – Plastic Blocks in the Studied Period
  • Percentage and Cumulative Share of Nonconformities in the Research Period
  • Pareto-Lorenz Diagram for the Nonconformities of Toys - Plastic Blocks
  • FMEA Method for the Analysis of the Toy Process - Plastic Blocks

Click on the following link to read the paper.

Developing an Internet of Things Assembly Line for Car Toys

In a  short paper titled “IoT Integrated Assembly Line - a conceptual model development for car toys assembly line” authors I. Kurniawan, S. Awibowo, and A.T. Pratama discuss their research to develop a conceptual model of an IoT (Internet of Things) based assembly line..

The authors discuss the internet of Things (IoT) and Cloud Manufacturing (CMfg) Integration into Lean Manufacturing.

The paper includes:

  • Design Architecture of IoT based Assembly Line
  • Car Toys Assembly Line
  • New Technology and Expected Impact

You can download a copy of the paper using the following link.

Making Toy Figurines

See the incredible process for making toy figurines in this video from How It’s Made.

You can watch the video here. 

 

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