The Peruvian furniture industry: an integration model for lean, Six Sigma and theory of constraints

Abstract

This research aims to analyse the results obtained from the combination of lean manufacturing, Six Sigma and theory of constraints in the wooden furniture industry in Peru. The research presents that there is increase in productivity of the SMEs by reducing the production time and costs without effecting the quality of the products. Based on a recent literature review, the authors, through the experience and study of Peruvian furniture companies, were able to identify an integrated model based on the five TOC steps, and the lean Six Sigma methods. A value chain of processes is proposed; highlighting elements that allow the elimination of activities that do not add value and control the variability of the critical process. Arena simulation was an important tool to validate proposals. This paper allows manufacturing managers to evaluate operating systems, in order to use integrated methodologies, and obtain the increase of Six Sigma levels by 50% and improve operational results by 6% in furniture manufacturing companies.