Improving Sigma Level of Galvanization Process by Zinc Over-Coating Reduction Using an Integrated Six Sigma and Design-of-Experiments Approach

2021 ◽  
Author(s):  
Neha Verma ◽  
Vinay Sharma ◽  
M. Affan Badar
Keyword(s):  
Design Of Experiments ◽  
Six Sigma ◽  
Sigma Level

scholarly journals A Case Study of Six Sigma Define-Measure-Analyze-Improve-Control (DMAIC) Methodology in Garment Sector

2017 ◽  
Vol 8 (4) ◽  
pp. 1309 ◽  
Author(s):  
Abdur Rahman ◽  
Salaha Uddin Chowdhury Shaju ◽  
Sharan Kumar Sarkar ◽  
Mohammad Zahed Hashem ◽  
S. M. Kamrul Hasan ◽  
...  
Keyword(s):  
Design Of Experiments ◽  
Analysis Of Variance ◽  
Six Sigma ◽  
Empirical Application ◽  
Sigma Level ◽  
Manufacturing Organization

This paper demonstrates the empirical application of Six Sigma and Define-Measure-Analyze-Improve-Control (DMAIC) methodology to reduce product defects within a garments manufacturing organization in Bangladesh which follows the DMAIC methodology to investigate defects, root causes and provide a solution to eliminate these defects. The analysis from employing Six Sigma and DMAIC indicated that the broken stitch and open seam influenced the number of defective products. Design of experiments (DOE) and the analysis of variance (ANOVA) techniques were combined to statistically determine the correlation of the broken stitch and open seam with defects as well as to define their optimum values needed to eliminate the defects. Thus, a reduction of about 35% in the garments defect was achieved, which helped the organization studied to reduce its defects and thus improve its Sigma level from 1.7 to 3.4.

scholarly journals Application of Six Sigma using Define Measure Analyze Improve Control (DMAIC) methodology in Garment Sector

2018 ◽  
Vol 9 (3) ◽  
pp. 810 ◽  
Author(s):  
Abdur Rahman ◽  
Salaha Uddin Chowdhury Shaju ◽  
Sharan Kumar Sarkar ◽  
Mohammad Zahed Hashem ◽  
S. M. Kamrul Hasan ◽  
...  
Keyword(s):  
Design Of Experiments ◽  
Analysis Of Variance ◽  
Six Sigma ◽  
Empirical Application ◽  
Sigma Level ◽  
Manufacturing Organization

This paper demonstrates the empirical application of Six Sigma and Define-Measure-Analyze-Improve-Control (DMAIC) methodology to reduce product defects within a garments manufacturing organization in Bangladesh which follows the DMAIC methodology to investigate defects, root causes and provide a solution to eliminate these defects. Design of experiments (DOE) and the analysis of variance (ANOVA) techniques were combined to statistically determine the correlation of the broken stitch and open seam with defects as well as to define their optimum values needed to eliminate the defects. The analysis from employing Six Sigma and DMAIC indicated that the broken stitch and open seam influenced the number of defective products. Thus, a reduction of about 35% in the garments defect was achieved, which helped the organization studied to reduce its defects and thus improve its Sigma level from 1.7 to 3.4.

Measure and Analyze the Problems of Concrete Mixture Production via Six Sigma DMAIC Tools: Central Concrete Mix Plant as a Case Study

2012 ◽  
Vol 622-623 ◽  
pp. 472-477
Author(s):  
Ali A. Karakhan ◽  
Angham E. Alsaffar
Keyword(s):  
Six Sigma ◽  
Business Strategy ◽  
Concrete Mixture ◽  
Statistical Tools ◽  
Sigma Level ◽  
Defect Rate ◽  
Concrete Production ◽  
Concrete Mix ◽  
Six Sigma Methodology

The aims of this study are to measure the defect rate and analyze the problems of production of ready concrete mixture plant by using Six Sigma methodology which is a business strategy for operations improvement depending basically on the application of its sub-methodology DMAIC improvement cycle and the basic statistical tools where the process sigma level of concrete production in the case study was 2.41 σ.

Six Sigma and Beyond: Design of Experiments

Technometrics ◽  
2004 ◽  
Vol 46 (4) ◽  
pp. 489-490 ◽  
Author(s):  
Thomas J Bzik
Keyword(s):  
Design Of Experiments ◽  
Six Sigma

scholarly journals Quality improvements on creative industry by using Six Sigma: a study case

2018 ◽  
Vol 154 ◽  
pp. 01088
Author(s):  
Dwi Adi Purnama ◽  
Riadho Clara Shinta ◽  
Vembri Noor Helia
Keyword(s):  
Six Sigma ◽  
Textile Industry ◽  
Fuzzy Ahp ◽  
Creative Economy ◽  
Creative Industry ◽  
Quality Improvements ◽  
Sigma Level ◽  
Study Case ◽  
And Control ◽  
Hierarchy Process

Indonesia has several creative economy sectors that rapidly developed and potentially can be improved to 7% annually. One of them is textile industry specifically bag industry. This industry’s development could enhance the production of commodities and emerge other SMEs to initiate the similar field. Therefore, to raise its profit, customer’s satisfaction must be elevated by minimizing defected products. In order to support it, an improvement on production process is a must. This research employs Six Sigma methods integration with Fuzzy Analytical Hierarchy Process (Fuzzy AHP)-Failure Mode and Effect Anlysis (FMEA). Six Sigma is designated to analyze the level of products’ defect through Define, Measure, Analyze, Improve, and Control (DMAIC) stages and assess the factors that cause the defects by using Fuzzy AHP decision support system and FMEA in risk analysis on defect. The result of the research shows the shortage of defects that demonstrated by DPMO indicator and Sigma level. It is identified that the number of DPMO was being reduced from 20003.75 to 11185.73. While Six Sigma level demonstrated the enhancement from 3.61 to 3.86. Those suggest that the improvement solution provides has significant effect on the defects decreasing at the bag convection industry.

scholarly journals QUALITY IMPROVEMENT ON CERAMIC TILES PROUCTION PROCESS WITH SIX SIGMA METHOD (DMAIC) AT PT ARWANA CITRAMULIA

2018 ◽  
Vol 3 (2) ◽  
pp. 101
Author(s):  
Priskila Christine Rahayu ◽  
Vanesa Darvin
Keyword(s):  
Quality Improvement ◽  
Production Process ◽  
Six Sigma ◽  
Ceramic Tiles ◽  
Control Approach ◽  
Sigma Level ◽  
And Control

This study focused on quality improvement on ceramic tiles production process at PT Arwana Citramulia. This study used data defects for 12 months (May 2016 – April 2017) and only focus on one type of defect and it is chop corner. Six sigma with DMAIC (define, measure, analyze, improve, and control) approach was used to improve the process. Each step of DMAIC was conducted to carefully analyze and keep the process precisely. The ceramic tiles production process contains a number of 4375 products defects in million opportunities (DPMO), with sigma level of 4.13. In the improve step of DMAIC, FMEA form was used to propose some recommendations in order to improve the process, some of that that are provision of lubricant periodically by the operator, polishing on the surface of the liner to clean and clear, examination and maintenance periodically. Keyword : Quality, Six Sigma, DMAIC, Defects.

scholarly journals ANALISIS KECACATAN KEMASAN PRODUK OKKY JELLY DRINK PERISA BLACKCURRANT SEBAGAI UPAYA PERBAIKAN KUALITAS DENGAN METODE DMAIC PADA PT. TRITEGUH MANUNGGAL SEJATI

2019 ◽  
Vol 3 (1) ◽  
Author(s):  
Suharto Suharto ◽  
Keyword(s):  
Quality Control ◽  
Production Process ◽  
Six Sigma ◽  
Cause And Effect ◽  
Sigma Level ◽  
Quality Control Tool ◽  
And Control ◽  
Cause And Effect Diagram ◽  
Control Tool

Abstract This study aims to determine and identify the causes of defects in the production process of PT. Triteguh Manunggal Sejati and know the level of sigma level. This research uses the six sigma method with the DMAIC approach as a quality control tool, which includes the Define, Measure, Analyze, Improve and Control stages. Based on this study the results obtained are the level of sigma level at PT.Triteguh Manunggal Sejati is 4.96, which means that in the stage of sigma level the company has not reached the level of six sigma levels because in the production process at PT.Triteguh Manunggal Sejati still has product defects in the production process not yet achieved zero defect. The causes of product defects are based on cause and effect diagrams namely lid / seal defects are leaky lid, broken lid, and tilted lid. Kata kunci : Defect, Six Sigma, DMAIC, cause and effect diagram

Reducing failure rate at high voltage (HV) testing of insulator using Six Sigma methodology

2018 ◽  
Vol 67 (5) ◽  
pp. 791-808 ◽  
Author(s):  
Darshak A. Desai ◽  
Aurangzeb Javed Ahmed Shaikh
Keyword(s):  
Failure Rate ◽  
High Voltage ◽  
Six Sigma ◽  
Manufacturing Industry ◽  
Small Scale ◽  
Case Study Methodology ◽  
Content Type ◽  
Sigma Level ◽  
Ceramic Manufacturing

PurposeThis paper, a case study, aims to illustrate the application of Six Sigma in a small-scale ceramic manufacturing industry. The purpose of this paper is to demonstrate the empirical application of DMAIC methodology to reduce failure rate at high voltage (HV) testing of one of the most critical products, insulator.Design/methodology/approachThe case study is based on primary data collected from a real-life situation prevailing in the industry. The case study methodology adopted here is at one small-scale unit wherein the authors have applied DMAIC methodology and observed and recorded the improvement results, especially, reduction in failure rate at HV testing of insulator and, thus, increase in Sigma level.FindingsThe results found after implementation of the solutions are very significant. The rejection percentage has been reduced from 0.5 to 0.1 percent and consequently the Sigma level has been improved from 4.4 to 5.0.Research limitations/implicationsThis success story can be a guiding roadmap for other such industries to successfully implement Six Sigma to improve quality, productivity and profitability.Practical implicationsThis case study will serve as one of the resource bases for the industries which have till not implemented Six Sigma and benefited from the same.Social implicationsImproved quality and productivity leads to better economy. This case will help industries to serve the society with better economy with improved quality and productivity.Originality/valueThough ceramic industries in India are having enormous potential for growth, majority of them, especially, small and medium industries are either not aware of or not implementing Six Sigma to reap its multidimensional benefits of improving quality, productivity and profitability. This study highlights the benefits reaped by small-scale ceramic manufacturing industry opening up the avenues for its application at other such organizations.

Design of experiments in the service industry: results from a global survey and directions for further research

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Jiju Antony ◽  
Elisabeth Viles ◽  
Alexandre Fonseca Torres ◽  
Marcelo Machado Fernandes ◽  
Elizabeth A. Cudney
Keyword(s):  
Design Of Experiments ◽  
Continuous Improvement ◽  
Process Improvement ◽  
Six Sigma ◽  
Service Sector ◽  
Success Factors ◽  
Service Industry ◽  
Quality Characteristics ◽  
Content Type ◽  
Critical Success

PurposeThe purpose of this study is to critically evaluate the current status of Design of experiments (DoE) in the service industry or non-manufacturing processes in the manufacturing sector. This involves the identification of critical success factors and challenges in the use of DoE in the context of the service industry as well as the key skills needed for its successful applications.Design/methodology/approachIn order to identify the critical success factors and challenges, an online survey instrument was developed and distributed across Six Sigma Black Belts (SSBB), Six Sigma Master Black Belts (SSMBB), process improvement champions, continuous improvement professionals, DoE experts and specialists as well as academics who are involved in DoE research and applications.FindingsA total of 109 participants from over 20 countries responded to the study. One of the first findings of the study is that over 40% of the process improvement professionals in the service sector do not have any hands-on experience with the application of DoE. Further, this study highlights the following critical factors for successful DoE applications: dedicating adequate resources in terms of time, budget and people for the experiment; getting a clear understanding of the problem at hand; securing a reliable and validated measurement system for measuring the response or quality characteristics of interest; and identifying input independent variables, which influence the quality characteristics during the brainstorming stage. Some respondents also mention the importance of having training or education in DoE as a critical success factor. At the same time, the lack of adequate planning to experimentation, mathematical knowledge and statistical reasoning remains as challenge to be solved.Research limitations/implicationsAs data were collected at an individual level, inter-reliability, which measures the consistency of judgements on a particular survey item, could not be gauged. Moreover, due to low sample size across some continents, an intercontinental comparative study on the extent of the application of DoE across various continents could not be performed.Originality/valueTo the best of the authors’ knowledge, this is the first global survey carried out to understand the status of DoE in the service industry. The results of the global study can be used to encourage quality, continuous improvement and process improvement professionals in the service sector to drive wider acceptance of one of the most powerful tools in the Six Sigma toolkit for problem-solving scenarios. Moreover, senior managers in the service industry can take away some of the key benefits, challenges and success factors in the implementation of DoE.

Six Sigma Robust Design of Composite Hand for LCD Glass Transfer Robot

2008 ◽  
Vol 33-37 ◽  
pp. 1451-1456 ◽  
Author(s):  
Hyun Wook Nam
Keyword(s):  
Layer Thickness ◽  
Robust Design ◽  
Six Sigma ◽  
Design Parameter ◽  
Beam Width ◽  
Coefficient Of Determination ◽  
Stacking Sequence ◽  
Pareto Chart ◽  
Sigma Level ◽  
Beam Height

This research studied robust design of composite hand for LTR (LCD glass Transfer Robot). 1st DOE (Design of Experiment) was conducted to find out vital few Xs. 108 experiments were performed and their results were statistically analyzed. Pareto chart analysis shows that the geometric parameters (height and width of composite beam) are more important than material parameters (E1, E2) or stacking sequence angle. Also, the stacking sequence of mid-layer is more important than that of outer-layer. The main effect plots show that the maximum deflection of LTR hand is minimized with increasing height, width of beam and layer thickness. 2nd DOE was conducted to obtain RSM (Response Surface Method) equation. 25 experiments were conducted. The CCD (Central Composite Design) technique with four factors was used. The coefficient of determination (R2) for the calculated RSM equation was 0.989. Optimum design was conducted using the RSM equation. Multi-island genetic algorithm was used to optimize. Optimum values for beam height, beam width, layer thickness and beam length were 24.9mm, 186.6mm, 0.15mm and 2402.4mm, respectively. An approximate value of 0.77mm in deflection was expected to be maximized under the optimum conditions. Six sigma robust design was conducted to find out guideline for control range of design parameter. To acquire six sigma level reliability, the standard deviation of design parameter should be controlled within 2% of average design value

Sign in / Sign up

Export Citation Format

Share Document