Lean and Six Sigma are used in the paint and coatings manufacturing industry to reduce defects, improve flow, and reduce waste. We’ll look at three cases from Saudi Arabia, DuPont, and United Arab Emirates. We’ll finish with an interesting video on the paint manufacturing process.


Using Lean Manufacturing Techniques in Paint Manufacturing: Saudi Arabia


In a case study titled “An Application of Lean Manufacturing Techniques in Paint Manufacturing Company: A Case Study,” authors Ahmed M. Badeeb, Reda M.S. Abdulaal, and Abdullah O. Bafail applied Lean tools in the pre-weighing, charging, and filling processes in a large Saudi paint manufacturing industry.

Tools applied to include:

  • Process Mapping
  • Value Stream Mapping
  • Fishbone Diagram
  • Workplace Organization, 5s
  • Single Minute Exchange of Die (SMED)
  • Work Standardization
  • Kanban

The authors detail the application and results from the tools used in each of the processes under study.

You can read the case study here.


Applying Six Sigma to Pigment Dispersant Demand Performance: DuPont


In a case study named “Using Six Sigma Tools to Evaluate Pigment Dispersant Demand Performance,” author Mary Koban from DuPont Titanium Technologies discusses the evaluation of the dispersant demand of four pigments using a Six Sigma approach.

The case looks at

  • Defining which parameters are important to measure
  • Performing the measurements
  • Analyzing the data
  • Drawing conclusions on the relative differences in dispersant demand

Tools used in the case study:

  • Cause and Effect Matrix
  • Data Collection Plan
  • Analysis of Variance (ANOVA)

You can access the case study here.

Applying Six Sigma Methodology to Eliminate Viscosity Defect Rate: United Arab Emirates


In a paper titled “Elimination of Viscosity Defect Rate of Acrylic White Flat Latex Paint Production Using Six Sigma Method” authors  Laarni C. Beciril and Beverly R. Blakemore discuss the work the quality control team conducted regarding product consistency in order to reduce the defect rate of acrylic white flat latex paint in a large paint company.

Methodology Applied:

  • Process Flow Chart
  • Standard Process Definition
    • Process, Critical to Function, and Standard
  • Raw Materials Definition
    • Critical to Function, and Standard
  • Finished Goods Specifications
  • Viscosity tracking by Batch
  • Gauge R and R study
  • Process Capability

The team project work led to the definition of more appropriate viscosity specification limits which in turn yielded a zero defect rate. This eliminated formulation adjustments needed in the past.

You can access the paper here.


Paint Manufacturing: How It’s Made


An interesting video from How It’s Made takes us from R&D to final shipping in the paint manufacturing process.



You can watch the video here.


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