OEE improvement through reducing start up duration using lean Six Sigma methodology in manufacturing

https://doi.org/10.35912/gabs.v1i1.3382
Published: Aug 27, 2025

Abstract:

Purpose: This study aims to improve Overall Equipment Effectiveness (OEE) by reducing start-up duration through the application of Lean Six Sigma methodology. This study focuses on identifying delays in the start-up process, determining their root causes, and implementing systematic improvements to enhance operational efficiency.

Research Methodology: A comprehensive case study was conducted in a manufacturing environment. Data related to the start-up duration, downtime causes, and other performance parameters were collected and analyzed. This study applied the Lean Six Sigma Define, Measure, Analyze, Improve, Control (DMAIC) framework to diagnose bottlenecks, identify inefficiencies, and design corrective actions that optimize start-up operations.

Results: The findings demonstrate that applying Lean Six Sigma tools significantly reduces startup delays, thereby improving OEE. The elimination of bottlenecks and process inefficiencies contributes to increased production output, enhanced operational performance, and greater competitiveness in a dynamic manufacturing environment.

Conclusions: Reducing the start-up duration using the Lean Six Sigma methodology provides a structured and effective approach to achieving operational excellence. This study confirms that targeted interventions in the start-up process can substantially improve equipment efficiency and overall manufacturing productivity.

Limitations: This research is limited to manufacturing industries where OEE is used as a primary performance indicator and may not be fully generalizable to the service sector.

Contribution: This study contributes to manufacturing excellence by combining Lean and Six Sigma practices to improve process efficiency and offer practical insights for industry practitioners.

Keywords:
1. E-commerce
2. Influencer Marketing
3. Local Culture
4. Security and Privacy
5. Social Commerce
Authors:
1 . Wijaya Khisbulloh
Institut Teknologi Bandung, Indonesia
2 . Gatot Yudoko
Institut Teknologi Bandung, Indonesia
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How to Cite
Khisbulloh, W., & Yudoko, G. (2025). OEE improvement through reducing start up duration using lean Six Sigma methodology in manufacturing. Global Academy of Business Studies, 1(1), 37–53. https://doi.org/10.35912/gabs.v1i1.3382
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Vol. 1 No. 1 (2024): July
Articles
References

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    Ahire, C. P., & Relkar, A. S. (2012). Correlating failure mode effect analysis (FMEA) & overall equipment effectiveness (OEE). Procedia Engineering, 38, 3482-3486. doi:https://doi.org/10.1016/j.proeng.2012.06.402

    Andersson, C., & Bellgran, M. (2015). On the complexity of using performance measures: Enhancing sustained production improvement capability by combining OEE and productivity. Journal of Manufacturing Systems, 35, 144-154.

    Azizi, A. (2015). Evaluation improvement of production productivity performance using statistical process control, overall equipment efficiency, and autonomous maintenance. Procedia Manufacturing, 2, 186-190. doi:https://doi.org/10.1016/j.promfg.2015.07.032

    Bârsan, R. M., & Codrea, F.-M. (2019). Lean university: applying the ECRS method to improve an administrative process. Paper presented at the MATEC Web of Conferences.

    Basera, V., Mwenje, J., & Ruturi, S. (2019). A snap on quality management in Zimbabwe: a perspectives review. Annals of Management and Organization Research, 1(2), 77-94. doi:https://doi.org/10.35912/amor.v1i2.278

    Beemaraj, R. K., & Prasath, A. (2018). SIX SIGMA CONCEPT AND DMAIC IMPLEMENTATION. 3.

    Bella, A., Swarnata, A., Vulovic, V., Nugroho, D., Meilissa, Y., Usman, U., & Dartanto, T. (2024). Macroeconomic impact of tobacco taxation in Indonesia. Tob Control, 33(Suppl 2), s108-s114. doi:https://doi.org/10.1136/tc-2022-057735

    da Silva, I. B., Godinho Filho, M., Agostinho, O. L., & Junior, O. F. L. (2019). A new Lean Six Sigma framework for improving competitiveness. Acta Scientiarum. Technology, 41, e37327. doi:https://doi.org/10.4025/actascitechnol.v41i1.37327

    Daneshjo, N., Rudy, V., Malega, P., & Krná?ová, P. (2021). Application of Spaghetti Diagram in Layout Evaluation Process: A Case Study. TEM Journal, 10, 573-582. doi:http://dx.doi.org/10.18421/TEM102-12

    Daniyan, I., Adeodu, A., Mpofu, K., Maladzhi, R., & Katumba, M. G. K.-K. (2022). Application of lean Six Sigma methodology using DMAIC approach for the improvement of bogie assembly process in the railcar industry. Heliyon, 8(3). doi:https://doi.org/10.1016/j.heliyon.2022.e09043

    De Mast, J., & Lokkerbol, J. (2012). An analysis of the Six Sigma DMAIC method from the perspective of problem solving. International Journal of Production Economics, 139(2), 604-614. doi:https://doi.org/10.1016/j.ijpe.2012.05.035

    Eakin, J. M., & Gladstone, B. (2020). “Value-adding” analysis: Doing more with qualitative data. International journal of qualitative methods, 19, 1609406920949333. doi:https://doi.org/10.1177/1609406920949333

    Ghorbani, S., & Khanachah, S. N. (2020). Investigating the reasons for failures and delays in R&D projects with the project management approach. Annals of Management and Organization Research, 1(4), 319-334. doi:https://doi.org/10.35912/amor.v1i4.553

    Gomaa, A. H. (2024). Improving productivity and quality of a machining process by using lean six sigma approach: A case study. Engineering Research Journal (Shoubra), 53(1), 1-16. doi:https://dx.doi.org/10.21608/erjsh.2023.226742.1194

    Jadhav, G. P., Jadhav, S. B., & Bhagat, A. (2015). Six sigma DMAIC literature review. International Journal of Scientific & Engineering Research, 6(12), 117-122. doi:https://doi.org/10.1108/ijlss-12-2012-0014

    Karam, A.-A., Liviu, M., Cristina, V., & Radu, H. (2018). The contribution of lean manufacturing tools to changeover time decrease in the pharmaceutical industry. A SMED project. Procedia Manufacturing, 22, 886-892. doi:https://doi.org/10.1016/j.promfg.2018.03.125

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    Knop, K., & Mielczarek, K. (2018). Using 5W-1H and 4M Methods to Analyse and Solve the Problem with the Visual Inspection Process-case study. Paper presented at the MATEC Web of Conferences.

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    Kotz, S., & Johnson, N. L. (2017). Process capability indices: Chapman and Hall/CRC.

    Kubiak, T. M., & Benbow, D. W. (2016). The certified six sigma black belt handbook: Quality Press.

    Latunusa, P. M., Timuneno, T., & Fanggidae, R. E. (2023). The effect of multiple role conflict and work stress on the performance of women nurses during the covid-19 with coping stress as intervening variables (Study at SoE Regional General Hospital). Journal of Multidisciplinary Academic and Practice Studies, 1(1), 53-67.

    Lee, D. K., In, J., & Lee, S. (2015). Standard deviation and standard error of the mean. Korean journal of anesthesiology, 68(3), 220.

    Lestari, S., Artisa, R. A., Nurliawati, N., & Maulana, R. R. (2025). Evaluation of the Affordable Food Program in Bandung City Using the CIPP Model. Jurnal Studi Ilmu Sosial dan Politik, 5(1), 85-100. doi:https://doi.org/10.35912/jasispol.v5i1.5197

    Mulla, M., Bhatwadekar, S., & Pandit, S. (2014). Implementation of lean manufacturing through the technique of Single Minute Exchange or Die (SMED) to reduce change over time. International Journal of Innovative Research in Science, Engineering and Technology, 3(6), 13069-13076.

    Mulyapradana, A., Aghus Jamaludin, K., Farikhul, M., Safna, S., & Nafiatul, M. (2025). Optimalisasi Layanan Desa Pedawang Melalui Sistem Kearsipan. Jurnal Studi Ilmu Sosial dan Politik, 5(1), 1-10. doi:https://doi.org/10.35912/jasispol.v5i1.4253

    Munro, R. A., Ramu, G., & Zrymiak, D. J. (2015). The certified six sigma green belt handbook: Quality Press.

    Nuzulianto, F. M., & Sukalumba, I. S. (2025). Analisis Dampak UU TNI 2025 Terhadap Potensi Terbentuknya Junta Militer. Jurnal Studi Ilmu Sosial dan Politik, 5(1), 43-54. doi:https://doi.org/10.35912/jasispol.v5i1.4481

    Odeyinka, O. F., Ipinnimo, O., & Ogunwolu, F. (2024). Parametric multi-level modeling of Lean Six Sigma. Journal of Engineering and Applied Science, 71(1), 193. doi:https://doi.org/10.1186/s44147-024-00528-1

    Otariyani, A., Nofrima, S., & Febriyanti, D. (2025). Analisis Tanggapan Pengemudi Ojek Online terhadap Penerapan E-Tilang di Kota Palembang 2024. Jurnal Studi Ilmu Sosial dan Politik, 5(1), 11-31. doi:https://doi.org/10.35912/jasispol.v5i1.4308

    Rizky, A. A., Suparto, D., & Florina, I. D. (2025). Analisis Pola Komunikasi dalam Disfungsional Family & Resiliensi pada Anak Kota Tegal. Jurnal Studi Ilmu Sosial dan Politik, 5(1), 69-84. doi:https://doi.org/10.35912/jasispol.v5i1.4616

    Schweikhart, S. A., & Dembe, A. E. (2009). The applicability of Lean and Six Sigma techniques to clinical and translational research. Journal of Investigative Medicine, 57(7), 748-755. doi:https://doi.org/10.231/JIM.0b013e3181b91b3a

    Seran, E. R., Kase, P., & Nursalam, N. (2022). The effect of competence, workload, and incentives on the interest of civil servants to become commitment-making officials in Malaka Regency. Annals of Human Resource Management Research, 2(1), 15-30. doi:https://doi.org/10.1007/978-3-031-93554-1_20

    Suhardi, B., Anisa, N., & Laksono, P. W. (2019). Minimizing waste using lean manufacturing and ECRS principle in Indonesian furniture industry. Cogent engineering, 6(1), 1567019. doi:https://doi.org/10.1080/23311916.2019.1567019

    Tenera, A., & Pinto, L. C. (2014). A Lean Six Sigma (LSS) project management improvement model. Procedia-Social and Behavioral Sciences, 119, 912-920. doi:https://doi.org/10.1016/j.sbspro.2014.03.102

    Zulfiqar, M. (2021). Six Sigma And Lean Approach For Enhanced Process Value Chain. doi:https://doi.org/10.5703/1288284317341

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  2. Ahire, C. P., & Relkar, A. S. (2012). Correlating failure mode effect analysis (FMEA) & overall equipment effectiveness (OEE). Procedia Engineering, 38, 3482-3486. doi:https://doi.org/10.1016/j.proeng.2012.06.402
  3. Andersson, C., & Bellgran, M. (2015). On the complexity of using performance measures: Enhancing sustained production improvement capability by combining OEE and productivity. Journal of Manufacturing Systems, 35, 144-154.
  4. Azizi, A. (2015). Evaluation improvement of production productivity performance using statistical process control, overall equipment efficiency, and autonomous maintenance. Procedia Manufacturing, 2, 186-190. doi:https://doi.org/10.1016/j.promfg.2015.07.032
  5. Bârsan, R. M., & Codrea, F.-M. (2019). Lean university: applying the ECRS method to improve an administrative process. Paper presented at the MATEC Web of Conferences.
  6. Basera, V., Mwenje, J., & Ruturi, S. (2019). A snap on quality management in Zimbabwe: a perspectives review. Annals of Management and Organization Research, 1(2), 77-94. doi:https://doi.org/10.35912/amor.v1i2.278
  7. Beemaraj, R. K., & Prasath, A. (2018). SIX SIGMA CONCEPT AND DMAIC IMPLEMENTATION. 3.
  8. Bella, A., Swarnata, A., Vulovic, V., Nugroho, D., Meilissa, Y., Usman, U., & Dartanto, T. (2024). Macroeconomic impact of tobacco taxation in Indonesia. Tob Control, 33(Suppl 2), s108-s114. doi:https://doi.org/10.1136/tc-2022-057735
  9. da Silva, I. B., Godinho Filho, M., Agostinho, O. L., & Junior, O. F. L. (2019). A new Lean Six Sigma framework for improving competitiveness. Acta Scientiarum. Technology, 41, e37327. doi:https://doi.org/10.4025/actascitechnol.v41i1.37327
  10. Daneshjo, N., Rudy, V., Malega, P., & Krná?ová, P. (2021). Application of Spaghetti Diagram in Layout Evaluation Process: A Case Study. TEM Journal, 10, 573-582. doi:http://dx.doi.org/10.18421/TEM102-12
  11. Daniyan, I., Adeodu, A., Mpofu, K., Maladzhi, R., & Katumba, M. G. K.-K. (2022). Application of lean Six Sigma methodology using DMAIC approach for the improvement of bogie assembly process in the railcar industry. Heliyon, 8(3). doi:https://doi.org/10.1016/j.heliyon.2022.e09043
  12. De Mast, J., & Lokkerbol, J. (2012). An analysis of the Six Sigma DMAIC method from the perspective of problem solving. International Journal of Production Economics, 139(2), 604-614. doi:https://doi.org/10.1016/j.ijpe.2012.05.035
  13. Eakin, J. M., & Gladstone, B. (2020). “Value-adding” analysis: Doing more with qualitative data. International journal of qualitative methods, 19, 1609406920949333. doi:https://doi.org/10.1177/1609406920949333
  14. Ghorbani, S., & Khanachah, S. N. (2020). Investigating the reasons for failures and delays in R&D projects with the project management approach. Annals of Management and Organization Research, 1(4), 319-334. doi:https://doi.org/10.35912/amor.v1i4.553
  15. Gomaa, A. H. (2024). Improving productivity and quality of a machining process by using lean six sigma approach: A case study. Engineering Research Journal (Shoubra), 53(1), 1-16. doi:https://dx.doi.org/10.21608/erjsh.2023.226742.1194
  16. Jadhav, G. P., Jadhav, S. B., & Bhagat, A. (2015). Six sigma DMAIC literature review. International Journal of Scientific & Engineering Research, 6(12), 117-122. doi:https://doi.org/10.1108/ijlss-12-2012-0014
  17. Karam, A.-A., Liviu, M., Cristina, V., & Radu, H. (2018). The contribution of lean manufacturing tools to changeover time decrease in the pharmaceutical industry. A SMED project. Procedia Manufacturing, 22, 886-892. doi:https://doi.org/10.1016/j.promfg.2018.03.125
  18. Kasemset, C., Pinmanee, P., & Umarin, P. (2014). Application of ECRS and simulation techniques in bottleneck identification and improvement: A paper package factory. Paper presented at the Proceedings of the Asia Pacific industrial engineering & management systems conference.
  19. Knop, K., & Mielczarek, K. (2018). Using 5W-1H and 4M Methods to Analyse and Solve the Problem with the Visual Inspection Process-case study. Paper presented at the MATEC Web of Conferences.
  20. Komakech, E., Obici, G., & Mwesigwa, D. (2021). Efficacy of inspirational motivation on the performance of public health workers in mid-north of Uganda. Annals of Human Resource Management Research (AHRMR), 1(2), 85-97.
  21. Kotz, S., & Johnson, N. L. (2017). Process capability indices: Chapman and Hall/CRC.
  22. Kubiak, T. M., & Benbow, D. W. (2016). The certified six sigma black belt handbook: Quality Press.
  23. Latunusa, P. M., Timuneno, T., & Fanggidae, R. E. (2023). The effect of multiple role conflict and work stress on the performance of women nurses during the covid-19 with coping stress as intervening variables (Study at SoE Regional General Hospital). Journal of Multidisciplinary Academic and Practice Studies, 1(1), 53-67.
  24. Lee, D. K., In, J., & Lee, S. (2015). Standard deviation and standard error of the mean. Korean journal of anesthesiology, 68(3), 220.
  25. Lestari, S., Artisa, R. A., Nurliawati, N., & Maulana, R. R. (2025). Evaluation of the Affordable Food Program in Bandung City Using the CIPP Model. Jurnal Studi Ilmu Sosial dan Politik, 5(1), 85-100. doi:https://doi.org/10.35912/jasispol.v5i1.5197
  26. Mulla, M., Bhatwadekar, S., & Pandit, S. (2014). Implementation of lean manufacturing through the technique of Single Minute Exchange or Die (SMED) to reduce change over time. International Journal of Innovative Research in Science, Engineering and Technology, 3(6), 13069-13076.
  27. Mulyapradana, A., Aghus Jamaludin, K., Farikhul, M., Safna, S., & Nafiatul, M. (2025). Optimalisasi Layanan Desa Pedawang Melalui Sistem Kearsipan. Jurnal Studi Ilmu Sosial dan Politik, 5(1), 1-10. doi:https://doi.org/10.35912/jasispol.v5i1.4253
  28. Munro, R. A., Ramu, G., & Zrymiak, D. J. (2015). The certified six sigma green belt handbook: Quality Press.
  29. Nuzulianto, F. M., & Sukalumba, I. S. (2025). Analisis Dampak UU TNI 2025 Terhadap Potensi Terbentuknya Junta Militer. Jurnal Studi Ilmu Sosial dan Politik, 5(1), 43-54. doi:https://doi.org/10.35912/jasispol.v5i1.4481
  30. Odeyinka, O. F., Ipinnimo, O., & Ogunwolu, F. (2024). Parametric multi-level modeling of Lean Six Sigma. Journal of Engineering and Applied Science, 71(1), 193. doi:https://doi.org/10.1186/s44147-024-00528-1
  31. Otariyani, A., Nofrima, S., & Febriyanti, D. (2025). Analisis Tanggapan Pengemudi Ojek Online terhadap Penerapan E-Tilang di Kota Palembang 2024. Jurnal Studi Ilmu Sosial dan Politik, 5(1), 11-31. doi:https://doi.org/10.35912/jasispol.v5i1.4308
  32. Rizky, A. A., Suparto, D., & Florina, I. D. (2025). Analisis Pola Komunikasi dalam Disfungsional Family & Resiliensi pada Anak Kota Tegal. Jurnal Studi Ilmu Sosial dan Politik, 5(1), 69-84. doi:https://doi.org/10.35912/jasispol.v5i1.4616
  33. Schweikhart, S. A., & Dembe, A. E. (2009). The applicability of Lean and Six Sigma techniques to clinical and translational research. Journal of Investigative Medicine, 57(7), 748-755. doi:https://doi.org/10.231/JIM.0b013e3181b91b3a
  34. Seran, E. R., Kase, P., & Nursalam, N. (2022). The effect of competence, workload, and incentives on the interest of civil servants to become commitment-making officials in Malaka Regency. Annals of Human Resource Management Research, 2(1), 15-30. doi:https://doi.org/10.1007/978-3-031-93554-1_20
  35. Suhardi, B., Anisa, N., & Laksono, P. W. (2019). Minimizing waste using lean manufacturing and ECRS principle in Indonesian furniture industry. Cogent engineering, 6(1), 1567019. doi:https://doi.org/10.1080/23311916.2019.1567019
  36. Tenera, A., & Pinto, L. C. (2014). A Lean Six Sigma (LSS) project management improvement model. Procedia-Social and Behavioral Sciences, 119, 912-920. doi:https://doi.org/10.1016/j.sbspro.2014.03.102
  37. Zulfiqar, M. (2021). Six Sigma And Lean Approach For Enhanced Process Value Chain. doi:https://doi.org/10.5703/1288284317341