Mobile phones are used in every country in the world. Lean and Six Sigma help in their production and distribution. We’ll look at three case studies from India, United Arab Emirates, and Brazil. We’ll finish with a video of how Samsung smartphones are made.
Applying Six Sigma DMAIC to Reduce Mobile Phone Soldering Defects: India
In a paper titled “Reducing soldering defects in a mobile phone manufacturing company: A DMAIC approach,” authors Anshula Garg, Kalhan Raina, and Richa Sharma cover the use of Six Sigma DMAIC phases in reducing soldering defects in mobile phone manufacturing.
Included in the article are:
- Soldering Defects ppm by Shift
- Cause and Effect Diagram for Soldering Defects
- Soldering Defects Improvement Trend: Phase 1 and 2 with detailed discussion
- Control Plan Sustainment Actions
Through the DMAIC application, assembly soldering defects were reduced from 3800 ppm to 200 ppm.
You can access the paper here.
[Citation: Anshula Garg et al 2020 IOP Conf. Ser.: Mater. Sci. Eng. 748 012027]
Applying Lean Six Sigma to Improve Mobile Order Fulfillment Process: United Arab Emirates
In an article titled “Using Lean Six Sigma to improve mobile order fulfillment process in a telecom service sector,” authors Mohammad Shamsuzzaman, Mariam Alzeraif, Imad Alsyouf and Michael Boon Chong Khoo cover the application of Lean Six Sigma tools through the DMAIC phases in order to reduce the mobile order fulfillment time.
Applied tools included:
- Pareto Chart of mobile order types
- Value Stream Map for current mobile order fulfillment process
- CTQ Specifications
- Data Collection Plan
- Process Capability Analysis
- Cause and Effect diagram for long order fulfillment lead-time
- Cause Validation through Gemba investigation
- Five-why Analysis for Invalid Order Information
- Lessons Learned
Through the implementation of the LSS methodology order fulfillment lead time for sales, orders were reduced from 10.3 days to 5.9 days. Value-added service order lead time went from 1.5 to o.5 days.
You can access the article here.
Lean Manufacturing Applied in a Cell Phone Company: Brazil
In a paper titled “Application of the Lean Manufacturing Culture: Case Study in a Cell Phone Company of the Industrial Pole of Manaus” authors Janderson da Silva Reis, Marden Eufrasio dos Santos, and David Barbosa de Alencar cover the application of Lean Manufacturing in a Brazilian cell phone company.
NOTE: Manaus is the capital and largest city of the Brazilian state of Amazonas.
In order to understand the company's needs, the project team used Value Steam Mapping, the Ishikawa Diagram, Pareto chart, and 5S tools.
After implementation, productivity increased from 289 units/hour to 340 units/hour with a reduction of one operator per shift.
You can read the article here.
Video of How Smart Phones are Made
In this video from Your Junction, we see how Samsung smartphones are made through a factory tour. You can watch the video here.
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