Enhancing process performance for composite padel racket manufacture using Six Sigma-DMAIC and VSM synergetic support

Abstract

In the mass production of composite materials, an unrealistic interpretation of specific parameters such as raw material consumption or cycle time per process may be counterproductive to business performance. This study proposes integrating a lean tool (Value Stream Map) into a DMAIC-based approach to improve process performance in composite padel racket manufacturing. The system presented is particularly useful in mass production as it is a customer-driven approach that aims to reduce waste (both material and time) and variation, thereby enhancing the quality of end-use composite products and their common manufacturing processes (cutting, laminating, and curing). The proposed procedure’s effectiveness in improving CoFRP processing within the sporting goods industry is noteworthy as cost savings and process performance have been increased by 18.5% and 15%, respectively, in workstations where advanced composite materials are processed.

Keywords

• composite production
• VSM
• DMAIC
• Lean Six Sigma
• case study