The objective of this research is to demonstrate the use of Lean Six Sigma methodology in a reduce high disposal scrap in hand lay-up process. Moreover, the goal is to develop working solutions for the target company to reduce the rework time through minimize the number of FOD defect. The theoretical background is achieved through exploring the literature of Lean and Six sigma. The fundamental of the composite material and composite fabrication method are studied due to this project conducted at the Aerospace Composite Malaysia Company. The FOD defect problem suggested by the target company, by following the Lean and Six Sigma improvement process DMAIC and by analysing the process data from the target company. The focus of this research is in demonstrating how to use Lean and Six Sigma improvement process DMAIC in practice. In order to validate the manufacturing system’s current state, improvement potential and solutions, statistical tools such as Pareto chart and histogram were used. To ensure that all the decisions were as heavily based on actual data as possible, the actual data had been analysed through cause and effect. As a result of this study, some designs have been done using tools. As a result of this research, a set of solutions were developed by poka yoke tool.. These quality technique are selected and applied to minimize in high disposal scrap.
