"Lean" Cables – Or Lean Approach in the Cable Industry

Abstract

Modernizing production systems and technical developments not only make production more efficient, but also focus on sustainability aspects. This multiple objective was also set by Prysmian MKM Kisteleki Cable Factory and, in the spirit of innovation, it successfully implemented a Lean Six Sigma (LSS) material use optimization project. The objective of this project was actually to optimize use of the masterbatch used during cable production. The title of the paper also suggests that the focus is on improving material efficiency, identified with the Lean approach. The implementation of the project was assisted by the five-step process of the DMAIC (Define, Measure, Analyze, Improve, Control) methodology, which provided a structured framework for the accurate measurement, analysis and control of material use. Introduction and application of the LSS methodology provided the opportunity for an in-depth examination of the production processes using statistical methods. By modifying the production system, the standard deviation of ~7.66% was reduced to 0.58%.