Reengineering Drill Systems: A Lean Six Sigma Approach  to Minimizing Defects and Maximizing Efficiency

Mostafa Mohammad; Adam Carlton Lynch

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Conference: 2025 ASEE -GSW Annual Conference
Location: Arlington, TX, Texas
Publication Date: March 9, 2025
Start Date: March 9, 2025
End Date: March 11, 2025
Page Count: 10
DOI: 10.18260/1-2--55074
Permanent URL: https://peer.asee.org/55074
Download Count: 48

Paper Authors

biography

Mostafa Mohammad Wichita State University

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MOSTAFA MOHAMMAD is currently a bachelor’s at Process Automation Engineering currently studying at Wichita State University. With a passion for optimising industrial processes that uses existing products, he has demonstrated the need of efficiency and quality improvement methodologies. For a recent project, Mostafa Mohammad has successfully applied all Six Sigma principles to enhance the production of an existing product, analysing and refining processes to achieve higher levels of precision and reliability as well as maintaining quality control. He also has involved in implementing of using innovative technologies to make operations more streamline and elevate overall performance. Besides studying, Mostafa has involved in working at Formula SAE in designing suspension systems for the race car

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Adam Carlton Lynch Wichita State University orcid.org/0000-0001-9495-1605

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ADAM CARLTON LYNCH received the BS and MS degrees in Industrial and Systems Engineering from the University of Southern California. He received his Master of International Management from the Thunderbird School of Management (part of Arizona State University). He completed a PhD in Industrial, Systems, and Manufacturing Engineering (ISME) from Wichita State University (WSU) in Kansas. Dr. Lynch has 30 years of global industry experience, particularly aerospace. Dr. Lynch now serves as an Associate Teaching Professor in the Applied Engineering department and as an Adjunct in ISME at WSU. His research interests include Engineering Education, Leadership, Mentoring and Lean Six Sigma.

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Abstract

Reengineering Drill Systems: A Lean Six Sigma Approach to Minimizing Defects and Maximizing Efficiency Mostafa Mohammad and Adam Carlton Lynch PhD Wichita State University

Abstract Objective: This project focuses on improving the efficiency of drill performance by redesigning its components to meet user needs. The primary goals are to optimize the drill's functionality, reduce defects, minimize production lead times, and achieve significant enhancements in operational performance and cost-effectiveness. Methods: The project begins with a comprehensive analysis of the existing drill design to identify inefficiencies and areas for improvement. Utilizing Lean Six Sigma methodologies in conjunction with machine element design principles, the team will evaluate the current performance and explore opportunities for optimization. By aligning the redesign with customer standards, the focus will be on enhancing operational efficiency, reducing defects, and improving overall reliability. The integration of these state-of-the-art design techniques ensures that the drill's components and functionality are optimized for durability, precision, and user satisfaction while maintaining cost-effectiveness and scalability. Results: Redesigning the drill using Lean Six Sigma methodologies is anticipated to not only increase its efficiency but also deliver significant cost savings and extended longevity. By optimizing the drill's components and processes, lead times for manufacturing and maintenance can be substantially reduced, allowing for quicker response to market demands. Additionally, the reduction in defects and improved reliability will lower maintenance requirements and associated costs. This streamlined approach will result in improved operational efficiency, decreased production expenses, and enhanced durability, ultimately leading to increased profitability and long-term value for both the manufacturer and the consumer. Conclusion: Redesigning products using Lean Six Sigma methodologies serves as a transformative approach to achieving higher efficiency, reduced defects, and greater customer satisfaction. By optimizing design and functionality, the projects can minimize lead times, reduce maintenance and production costs, and enhance product’s longevity. These improvements are essential for maintaining competitiveness, ensuring long-term sustainability, and delivering substantial financial and operational benefits, solidifying a product’s brand position in their respective market. Keywords: Lean, Six Sigma, Design

Citation
Format

Mohammad, M., & Lynch, A. C. (2025, March), Reengineering Drill Systems: A Lean Six Sigma Approach to Minimizing Defects and Maximizing Efficiency Paper presented at 2025 ASEE -GSW Annual Conference, Arlington, TX, Texas. 10.18260/1-2--55074

TY  - CPAPER
AB  - Reengineering Drill Systems: A Lean Six Sigma Approach 
to Minimizing Defects and Maximizing Efficiency
Mostafa Mohammad and Adam Carlton Lynch PhD
Wichita State University

Abstract
Objective: 
This project focuses on improving the efficiency of drill performance by redesigning its components to meet user needs. The primary goals are to optimize the drill&#39;s functionality, reduce defects, minimize production lead times, and achieve significant enhancements in operational performance and cost-effectiveness. 
Methods: 
The project begins with a comprehensive analysis of the existing drill design to identify inefficiencies and areas for improvement. Utilizing Lean Six Sigma methodologies in conjunction with machine element design principles, the team will evaluate the current performance and explore opportunities for optimization. By aligning the redesign with customer standards, the focus will be on enhancing operational efficiency, reducing defects, and improving overall reliability. The integration of these state-of-the-art design techniques ensures that the drill&#39;s components and functionality are optimized for durability, precision, and user satisfaction while maintaining cost-effectiveness and scalability. 
Results: 
Redesigning the drill using Lean Six Sigma methodologies is anticipated to not only increase its efficiency but also deliver significant cost savings and extended longevity. By optimizing the drill&#39;s components and processes, lead times for manufacturing and maintenance can be substantially reduced, allowing for quicker response to market demands. Additionally, the reduction in defects and improved reliability will lower maintenance requirements and associated costs. This streamlined approach will result in improved operational efficiency, decreased production expenses, and enhanced durability, ultimately leading to increased profitability and long-term value for both the manufacturer and the consumer. 
Conclusion: 
Redesigning products using Lean Six Sigma methodologies serves as a transformative approach to achieving higher efficiency, reduced defects, and greater customer satisfaction. By optimizing design and functionality, the projects can minimize lead times, reduce maintenance and production costs, and enhance product’s longevity. These improvements are essential for maintaining competitiveness, ensuring long-term sustainability, and delivering substantial financial and operational benefits, solidifying a product’s brand position in their respective market.
Keywords: Lean, Six Sigma, Design

AU  - Mostafa Mohammad
AU  - Adam Carlton Lynch
CY  - Arlington, TX, Texas
DA  - 2025/03/09
PB  - ASEE Conferences
TI  - Reengineering Drill Systems: A Lean Six Sigma Approach  to Minimizing Defects and Maximizing Efficiency
UR  - https://peer.asee.org/55074
DO  - 10.18260/1-2--55074
ER  -