Cigarette Reject Rate Reduction using a Lean Six Sigma Approach

Abstract: Due to changes in customer demands, companies often need to improve their processes and approach them in different ways. Waste elimination is very important for every company in their quest to reduce costs and use resources efficiently. Variation reduction helps keep processes steady and more accurate. Two powerful tools for process improvement are Lean and Six Sigma, when combined can bring many benefits to organizations that decide to implement them. The amount of continuous improvement tools that each methodology possesses brings the team a great variety of resources to attack and reduce variation in any process. Lean and Six Sigma methodologies have gain a lot of popularity in recent years. The improvements they bring to companies not only in an economical but as a way to develop professionals are impressive. These methodologies are changing mindsets worldwide and giving quality a new meaning. Lean Six Sigma certifications are a must for every professional looking to improve processes in their organization. Philip Morris International subsidiary in San Jose, Costa Rica has a great challenge on trying to improve processes in their production facilities to keep with goals and demands from headquarters in Laussane, Switzerland. This project is involved with the use of Lean and Six Sigma tools to improve the cigarette reject rate in the Marlboro line at Philip Morris. The project is divided in three parts. First an introduction to Lean and Six Sigma and why they are so important for companies now a days. Second, explain the DMAIC methodology used for the realization of the project. Third, explain the implementations made to improve the process and reduce cigarette reject rate.