Prediction and improvement of iron casting quality through analytics and Six Sigma approach

2019 ◽  
Vol 10 (1) ◽  
pp. 189-210 ◽  
Author(s):  
Nandkumar Mishra ◽  
Santosh B. Rane
Keyword(s):  
Data Analysis ◽  
Chemical Composition ◽  
Prediction Model ◽  
Six Sigma ◽  
Historical Data ◽  
Literature Survey ◽  
Manufacturing Processes ◽  
Iron Casting ◽  
Content Type ◽  
Six Sigma Approach

Purpose The purpose of this technical paper is to explore the application of analytics and Six Sigma in the manufacturing processes for iron foundries. This study aims to establish a causal relationship between chemical composition and the quality of the iron casting to achieve the global benchmark quality level. Design/methodology/approach The case study-based exploratory research design is used in this study. The problem discovery is done through the literature survey and Delphi method-based expert opinions. The prediction model is built and deployed in 11 cases to validate the research hypothesis. The analytics helps in achieving the statistically significant business goals. The design includes Six Sigma DMAIC (Define – Measure – Analyze – Improve and Control) approach, benchmarking, historical data analysis, literature survey and experiments for the data collection. The data analysis is done through stratification and process capability analysis. The logistic regression-based analytics helps in prediction model building and simulations. Findings The application of prediction model helped in quick root cause analysis and reduction of rejection by over 99 per cent saving over INR6.6m per year. This has also enhanced the reliability of the production line and supply chain with on-time delivery of 99.78 per cent, which earlier was 80 per cent. The analytics with Six Sigma DMAIC approach can quickly and easily be applied in manufacturing domain as well. Research limitations implications The limitation of the present analytics model is that it provides the point estimates. The model can further be enhanced incorporating range estimates through Monte Carlo simulation. Practical implications The increasing use of prediction model in the near future is likely to enhance predictability and efficiencies of the various manufacturing process with sensors and Internet of Things. Originality/value The researchers have used design of experiments, artificial neural network and the technical simulations to optimise either chemical composition or mould properties or melt shop parameters. However, this work is based on comprehensive historical data-based analytics. It considers multiple human and temporal factors, sand and mould properties and melt shop parameters along with their relative weight, which is unique. The prediction model is useful to the practitioners for parameter simulation and quality enhancements. The researchers can use similar analytics models with structured Six Sigma DMAIC approach in other manufacturing processes for the simulation and optimisations.

Credit card account opening excellence using six sigma methodology

2016 ◽  
Vol 7 (3) ◽  
pp. 294-323 ◽  
Author(s):  
Samsul Islam
Keyword(s):  
Process Improvement ◽  
Six Sigma ◽  
Credit Card ◽  
Current Knowledge ◽  
Case Study Methodology ◽  
Content Type ◽  
Study Results ◽  
Six Sigma Methodology ◽  
Six Sigma Approach ◽  
Opening Process

Purpose This study aims to expand the current knowledge of the Six Sigma approach in a period of time when there is little direct evidence of the need to improve the credit card account opening process. This is an important but neglected area of focus in the Six Sigma literature. This study explores the extent to which process improvement practices are extended to the credit card department. Design/methodology/approach A case study methodology is adopted in this study to facilitate an exploration of the implemented Six Sigma approach in the credit card department of a leading commercial bank. The process improvement tool used is the define, measure, analyze, improve and control (DMAIC) cycle. Findings The study’s results confirm that the Six Sigma approach improves the quality of the credit card account opening process. So, the Six Sigma approach can account for a reduced number of keying-in errors, resulting in better data accuracy and improved customer satisfaction. Research limitations/implications The authors, in an attempt to render the study results more feasible for data collection, have chosen to focus on the process of the new accounts unit of the credit card department. Therefore, the authors have not taken into account the other units (e.g. transaction processing) of the same department. Practical implications The results of this study will be useful in persuading bank management to evaluate and implement the Six Sigma approach. Hence, this research will assist bank managers with replies to questions, such as: “What impact will Six Sigma have on process-centric improvement, such as the new accounts opening process of a credit card department?” Originality/value Within the literature on the Six Sigma practice, there is little research that focuses on the implementation of this particular toolset especially for credit card departments. This indicates a gap in the field. A new contribution to bridging that gap comes from the analysis of the results for the Six Sigma concept, which addresses the new accounts opening process.

Defects Reduction in Spheroidal Graphite Iron Casting Process of a Jackscrew Manufacturer

2021 ◽  
Vol 891 ◽  
pp. 174-182
Author(s):  
Supachart Muangyai ◽  
Parames Chutima
Keyword(s):  
Six Sigma ◽  
Process Capability ◽  
Casting Process ◽  
End Users ◽  
Spheroidal Graphite ◽  
Iron Casting ◽  
Spheroidal Graphite Iron ◽  
Six Sigma Approach

This research focused on defects reduction in spheroidal graphite iron casting process of a jackscrew manufacturer in which graphite nodularity was lower than a given specification (75%). This situation could lead to serious issues and accident to end-users. The Six Sigma approach of DMAIC was employed to identify and eliminate the problems. The result obtained after implementing the Six Sigma showed that the process capability was improved from-0.47 to 2.04, and the average per cent graphite nodularity was increased significantly from 61.49% to 86.43%.

Data-driven quality improvement approach to reducing waste in manufacturing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Rose Clancy ◽  
Dominic O'Sullivan ◽  
Ken Bruton
Keyword(s):  
Supply Chain ◽  
Supply Chain Management ◽  
Quality Management ◽  
Process Improvement ◽  
Six Sigma ◽  
Data Driven ◽  
Manufacturing Processes ◽  
Management Performance ◽  
Chain Management ◽  
Content Type

PurposeData-driven quality management systems, brought about by the implementation of digitisation and digital technologies, is an integral part of improving supply chain management performance. The purpose of this study is to determine a methodology to aid the implementation of digital technologies and digitisation of the supply chain to enable data-driven quality management and the reduction of waste from manufacturing processes.Design/methodology/approachMethodologies from both the quality management and data science disciplines were implemented together to test their effectiveness in digitalising a manufacturing process to improve supply chain management performance. The hybrid digitisation approach to process improvement (HyDAPI) methodology was developed using findings from the industrial use case.FindingsUpon assessment of the existing methodologies, Six Sigma and CRISP-DM were found to be the most suitable process improvement and data mining methodologies, respectively. The case study revealed gaps in the implementation of both the Six Sigma and CRISP-DM methodologies in relation to digitisation of the manufacturing process.Practical implicationsValuable practical learnings borne out of the implementation of these methodologies were used to develop the HyDAPI methodology. This methodology offers a pragmatic step by step approach for industrial practitioners to digitally transform their traditional manufacturing processes to enable data-driven quality management and improved supply chain management performance.Originality/valueThis study proposes the HyDAPI methodology that utilises key elements of the Six Sigma DMAIC and the CRISP-DM methodologies along with additions proposed by the author, to aid with the digitisation of manufacturing processes leading to data-driven quality management of operations within the supply chain.

A framework for Six Sigma project selection in higher educational institutions, using a weighted scorecard approach

2015 ◽  
Vol 23 (1) ◽  
pp. 30-46 ◽  
Author(s):  
Monica C. Holmes ◽  
Lawrence O. Jenicke ◽  
Jessica L. Hempel
Keyword(s):  
Six Sigma ◽  
Selection Process ◽  
Educational Institution ◽  
Project Selection ◽  
Project Leader ◽  
Content Type ◽  
Help Desk ◽  
Use Of Time ◽  
Higher Educational ◽  
Six Sigma Approach

Purpose – This paper discusses the importance of the Six Sigma selection process, describes a Six Sigma project in a higher educational institution and presents a weighted scorecard approach for project selection. Design/methodology/approach – A case study of the Six Sigma approach being used to improve student support at a university computer help desk was used. An error related to the timeliness of service was defined and improved over the course of the project. Findings – The Six Sigma approach was useful for improving timely service, but a methodology for selecting the project was needed by the project leader. Using such a methodology would have ensured higher probability of project success. Practical implications – This framework provides directions for selecting a Six Sigma project in a higher educational setting. The weighted scorecard method is presented and may be used for selecting a project which would likely be the most efficient use of time and resources. Originality/value – While project selection methodologies have been published with regard to Six Sigma projects in business, this paper fills the need for selection criteria as they relate to higher educational settings.

Benchmarking academics through sustainable assessment criteria: an Indian case study

2015 ◽  
Vol 22 (3) ◽  
pp. 505-536 ◽  
Author(s):  
Bikram Jit Singh ◽  
Rakesh Joshi
Keyword(s):  
Six Sigma ◽  
Fine Tuning ◽  
Assessment Criteria ◽  
Academic Excellence ◽  
Engineering System ◽  
Present System ◽  
Content Type ◽  
Internal Assessment ◽  
Six Sigma Approach

Purpose – The purpose of this paper is to primarily emphasize on improvement of student’s academic excellence through devising and implementing a competent Internal Assessment Criteria that indirectly improves their results and passing rates in exams. Design/methodology/approach – In present system, Internal Assessment Criteria has evolved as critical factor having lot of margin for bringing improvement in student’s academics by redesigning or editing the existing one, appropriately. Assessment criteria are re-optimized by strategic implementation of well proved Six Sigma’s DMAIC approach. Findings – It is a one of rarely seen effort to transform Assessment Criteria by identifying the statistical relations between internal marks and external marks secured by students in an end semester university exams. The proposed framework and its validation through an Indian case study, ignites the application of this structured Six Sigma approach in higher education for necessary excellence. Research limitations/implications – The whole work revolves around the Indian engineering environments, moreover the case has been restricted and elaborate facts for only unaided (private) engineering universities. Practical implications – The paper can be utilized to stimulate thinking about the fine tuning of Assessment Criteria through proven Six Sigma methodology in current Indian academic settings and further safeguarding the interests of managements, students and society, simultaneously. Originality/value – The formulation of upcoming challenges before Indian engineering system are outcome of intense literature survey. Focussing on always neglected “Assessment Criteria” and its re-optimization by statistical approach of Six Sigma is hard to found and has immense scope in future for reaching at desired academic hikes.

A DMAIC Six Sigma approach to quality improvement in the anodising stage of the amplifier production process

2018 ◽  
Vol 35 (9) ◽  
pp. 1868-1880 ◽  
Author(s):  
Pallavi Sharma ◽  
Suresh Chander Malik ◽  
Anshu Gupta ◽  
P.C. Jha
Keyword(s):  
Quality Improvement ◽  
Production Process ◽  
Six Sigma ◽  
Shop Floor ◽  
Manufacturing Firm ◽  
Content Type ◽  
Root Cause ◽  
Six Sigma Methodology ◽  
Six Sigma Approach ◽  
Current Reality

Purpose The purpose of this paper is to study the anodising process of a portable amplifier production process to identify and eliminate the sources of variations, in order to improve the process productivity. Design/methodology/approach The study employs the define-measure-analyse-improve-control (DMAIC) Six Sigma methodology. Within the DMAIC framework various tools of quality management such as SIPOC analysis, cause and effect diagram, current reality tree, etc., are used in different stages. Findings High rejection rate was found to be the main problem leading to lower productivity of the process. Four types of defects were identified as main cause of rejections in the baseline process. Pareto analysis resulted in detection of the top defects, which were then analysed in details to find the root cause of the problem. Further study resulted in finding improvement measures that were discussed with the management before implementation. The process is sampled again to check the improvements, and control measures were established. Practical implications The study provides a framework for implementation of DMAIC Six Sigma methodology for a manufacturing firm. The results presented are based on the data collected from the shop floor. Results and findings of the study were implemented for quality improvement of the process. Originality/value The study is based on an original research conducted with the objective of quality improvement in the anodising process of the production process. Besides presenting an approach to DMAIC Six Sigma methodology, an application of the current reality tree tool for root cause analysis is presented, a tool used limitedly in the Six Sigma studies. The tool finds its uniqueness in its ability to address problems relating multiple factors than isolated factors.

Humming noise reduction of ceiling fan in the mass production applying DMAIC-six sigma approach

2020 ◽  
Vol 18 (1) ◽  
pp. 106-121
Author(s):  
Rubel Ahammed ◽  
Md. Zahid Hasan
Keyword(s):  
Six Sigma ◽  
Hypothesis Test ◽  
Process Condition ◽  
Poor Quality ◽  
Air Gap ◽  
Content Type ◽  
The Poor ◽  
And Control ◽  
Six Sigma Approach

Purpose Success and business reputation depend upon the quality of products where product quality depends upon the capability of a process, yield value and sigma score, etc. Poor quality of ceiling fan and mass rejection from quality check resulted in an alarming amount of cost for rework. As a result, the fulfillment of the production target was getting difficult day by day. The main purpose of this research is to identify the crucial causes for humming noise of ceiling fans and control it to a tolerable level so that maximum quality can be achieved. Design/methodology/approach The poor quality of ceiling fans was determined from the Pareto analysis of the define, measure, analyze, improve and control model which was humming noise during running and further actions were undertaken regarding the reduction of the humming noise. Project charter was formed before initiating the measure phase to study the suppliers, inputs, processes, outputs and customers diagram with process parameters and existing noise data were collected from random samples to determine the rolled throughput yield (94.95% existing) and existing sigma score which value of 3.14 and also the poor value (1.05) of process potential index implied that the process condition was below standard (<1.33) and need to be improved badly. Then root causes analysis and relationship diagram was prepared to identify the possible causes and with the design of experiments and correlation analysis, it was clear that the air gap between the stator and rotor was the main culprit behind the humming noise. Findings The minimum value of air gap was determined from boxplot analysis which was 0.2 mm–0.225 mm and the corresponding mean, the minimum and maximum value of sound level in dB (37.5–40.3 dB) for 0.225 mm air gap with the watt consumption (83 w) from the hypothesis test for the corresponding air gap. Finally, the updated sigma score and process capability analysis were performed with control charts to show the comparison after applying the DMAIC-six sigma methodology. The final sigma score was 5.1 which indicates a significant improvement of the process with the capability of saving US$23,438/year caused by the poor quality of ceiling fans. Practical implications Only quantitative values of the causes behind the humming noise were possible to identify. Other trivial many causes elimination might improve the sigma score closer to 6.00. The final sigma score that was achieved from this research was sustainable. Originality/value A structural approach with proper data analysis and application of various tools to detect the actual cause behind the humming noise of ceiling fans with numerical value has not been found in any literature. This research study can be a valuable asset for ceiling fan mass producers.

An examination of changing patterns in Lean Six Sigma research

2019 ◽  
Vol 27 (7) ◽  
pp. 23-25
Keyword(s):  
Six Sigma ◽  
Keyword Search ◽  
Fixed Time ◽  
Lean Six Sigma ◽  
Integrated System ◽  
Content Type ◽  
Time Period ◽  
Changing Patterns ◽  
Six Sigma Methodology ◽  
Six Sigma Approach

Purpose The purpose of this study was to examine patterns in the research contributions from individuals in the field to detect whether they reflect the evolution of academic discussion concerning integration of Lean and Six Sigma methodology over a fixed time period. Design/methodology/approach Data was gathered from a keyword search of articles in the SCOBUS data base to determine the most frequent contributors in the areas of Lean, Six Sigma and Lean Six Sigma research. Searches were carried out over five-yearly intervals from 2000 to 2015 and the twenty-one top contributors in each time period were identified. Findings The findings show that research contributions have moved away from looking at the single methodologies of Lean and Six Sigma and towards research based on the integrated Lean Six Sigma approach. The analysis also suggested that researchers may be publishing papers using different methodologies in response to different challenges in selecting the most appropriate tools to meet the needs of the specific issues they are addressing rather than advocating a particular approach. Practical implications For organizations to optimize performance a flexible approach would be beneficial with consideration being given to the specific issue and the correct tools and methodology selected from an integrated system or from Lean or Six Sigma systems alone. Originality/value This paper has originality in its’ consideration of the patterns of research contributions over a fixed time period as a reflection of the shift in debate from exclusive Lean or Six Sigma approaches to a more integrated Lean Six Sigma system.

A lean six sigma approach for improving university campus office moves

2019 ◽  
Vol 10 (4) ◽  
pp. 928-947 ◽  
Author(s):  
Jennifer Wheeler-Webb ◽  
Sandra L. Furterer
Keyword(s):  
Standard Deviation ◽  
Six Sigma ◽  
Lean Six Sigma ◽  
Similar Process ◽  
University Campus ◽  
Content Type ◽  
Control Methodology ◽  
Six Sigma Approach ◽  
Improvement Effort

Purpose The purpose of this study was to improve the quoting, scheduling, invoicing and paying for campus office moves at a university. The Lean Six Sigma project goal was to improve the campus office move process by making it less complicated, free-up program managers’ time and pay the vendor on time. Design/methodology/approach The team used the Lean Six Sigma Define-Measure-Analyze-Improve-Control methodology to improve the process. Findings The average time from the campus move to when the invoice was paid improved by 27%, with an improved median of 16%. The standard deviation was greatly reduced by 51%. The average invoiced date to paid date remained statistically the same, and the median increased from 20 to 30 days, due to a policy change to move the target from 20 to 30 days. The standard deviation of the invoice to paid date was greatly reduced by 38%. This was a successful project because the sponsors were on-board from the beginning and included the process owners in the improvement effort. Originality/value Other higher education institutions or other industry areas with a similar process can implement this methodology and processes outlined in this case study to improve efficiency and cost effectiveness and as a guide for improving other processes within institutions.

Six Sigma in education

2017 ◽  
Vol 25 (1) ◽  
pp. 91-108 ◽  
Author(s):  
Paul G. LeMahieu ◽  
Lee E. Nordstrum ◽  
Elizabeth A. Cudney
Keyword(s):  
Quality Improvement ◽  
Six Sigma ◽  
Work Processes ◽  
Content Type ◽  
Organizational Work ◽  
School Community Partnership ◽  
The Cost ◽  
And Control ◽  
Six Sigma Approach

Purpose This paper is one of seven in this volume that aims to elaborate different approaches to quality improvement in education. It delineates a methodology called Six Sigma. Design/methodology/approach The paper presents the origins, theoretical foundations, core principles and a case study demonstrating an application of Six Sigma in a school-community partnership in Milwaukee, Wisconsin. Findings The core principles underlying the approach are decreasing variability or unreliability in organizational work processes, eliminate waste or activity that does not add value to desired outcomes, identify defects and decrease their incidence, reduce the cost of work processes, and improve beneficiary/client satisfaction levels. The steps in this statistics-dependent method are design, measure, analyze, improve and control. Originality/value Few theoretical treatments and demonstration cases are currently available on commonly used models of quality improvement that might have potential value in improving education systems internationally. This paper fills this gap by elucidating one promising approach. The paper also derives value as it permits a comparison of the Six Sigma approach with other quality improvement approaches treated in this volume.

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