The Lean Six Sigma approach—herein referred to as the DMAIC cycle (Define, Measure, Analyze, Improve, Control)—is employed for this project to address a persistent inventory management problem at MidOpt, a machine vision solutions firm specializing in optical solutions. The task was to improve the accuracy of ERP inventory levels and reduce material waste for a specific part number, BP635-25.5. The project applied a rigorous methodology to define the problem, quantify critical performance measures (such as inventory variance and lost material yield opportunities), and identify root causes using process mapping, failure mode analysis, and hypothesis testing. After the issues were identified, corresponding solutions were designed and validated through pilot runs. Solutions ultimately implemented included normalizing work order forms, altering ERP processes, and strengthening departmental alignment. Although the project had insignificant monetary effects, it equated to high levels of internal customer satisfaction and operational consistency. The exercise was also a real-life demonstration of Lean Six Sigma methodology, demonstrating the power of data-driven problem-solving to perpetuate process improvement in factory settings.

Outgoing