An application of Six Sigma methodology for improving the first pass yield of a grinding process

2014 ◽  
Vol 25 (1) ◽  
pp. 125-135 ◽  
Author(s):  
E.V. Gijo ◽  
Jiju Antony ◽  
Maneesh Kumar ◽  
Rodney McAdam ◽  
Jose Hernandez
Keyword(s):  
Six Sigma ◽  
Grinding Process ◽  
Content Type ◽  
Study Approach ◽  
Automotive Company ◽  
First Pass ◽  
Six Sigma Methodology ◽  
Tools And Techniques ◽  
Real World Situation

Purpose – The purpose of this paper is to illustrate the power of the Six Sigma methodology in improving the first pass yield of a high-precision grinding process in the manufacture of automotive products. Design/methodology/approach – The paper follows a case study approach showing how theory has been put into practice. The case study was executed in a leading automotive company based in India. Findings – The application of the Six Sigma methodology resulted in a reduction of tolerance-related problems and improved the first pass yield from 85 to over 99 per cent. A number of tools and techniques in the Six Sigma tool box have been utilised for data analysis and drawing valid and sound conclusions. The implementation of the Six Sigma methodology has demonstrated a saving of US$70,000 in addition to the customer-facing benefits of improved quality on returns and sales. Practical implications – The results of the case study have provided greater stimulus within the production facilities for wider application of the methodology as a powerful problem solving methodology. Moreover, this case study sets the foundation for many other projects within the business. Originality/value – The paper is valuable to many Six Sigma black belts, practitioners of Six Sigma and researchers in terms of understanding the systematic application of the methodology in a real world situation.

Application of Six Sigma to minimize the defects in glass manufacturing industry

2019 ◽  
Vol 16 (4) ◽  
pp. 594-624 ◽  
Author(s):  
Narottam Yadav ◽  
Kaliyan Mathiyazhagan ◽  
Krishna Kumar
Keyword(s):  
Six Sigma ◽  
Manufacturing Industry ◽  
Poor Performance ◽  
Service Industries ◽  
Practical Implementation ◽  
Content Type ◽  
Six Sigma Methodology ◽  
Tools And Techniques ◽  
And Control

PurposeThe purpose of this paper is to improve the yield of a particular model of a car windshield, as the organization faces losses due to poor performance and rejection.Design/methodology/approachThe Six Sigma DMAIC (define, measure, analyze, improve and control) methodology is used to reduce variation and defects in the process. It is a methodology based on data-driven and fact-based analysis to find out the root cause of the problem with the help of statistical analysis. A worst performing model is selected as a case study through the scoping tree. The preprocess, printing, bending and layup process defects are reduced by analyzing the potential causes and hypothesis testing.FindingsThis paper describes Six Sigma methodology in a glass manufacturing industry in India for automotive applications. The overall yield of a car windshield achieved 93.57 percent against the historical yield of 88.4 percent, resulting in saving 50 lacs per annum. Due to no rework or repairing in the glass, low first-time yield causes major losses. Process improvement through focused cross-functional team reduces variation in the process. Six Sigma improves profitability and reduces defects in the automotive glass manufacturing process.Research limitations/implicationsThis case study is applied in automotive glass manufacturing industries. For service and healthcare industries, a similar type of study can be performed. Further research on the common type of processor industry would be valuable.Practical implicationsThe case study can be used as a problem-solving methodology in manufacturing and service industries. The tools and techniques can be used in other manufacturing processes also. This paper is useful for industries, researchers and academics for understanding Six Sigma methodology and its practical implementation.Originality/valueThis case study is an attempt to solve automobile glass manufacturing problems through DMAIC approach. The paper is a real case study showing benefits of Six Sigma implementation in the manufacturing industry and saving an annual cost of 50 lacs due to rejections in the process.

Competitive advantage through Six Sigma in sand casting industry to improve overall first-pass yield: a case study of SSE

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Mihir Solanki ◽  
Darshak Desai
Keyword(s):  
Six Sigma ◽  
Sand Casting ◽  
Small Scale ◽  
Productivity Improvement ◽  
Content Type ◽  
Foundry Industry ◽  
Road Map ◽  
First Pass ◽  
Six Sigma Methodology

Purpose The purpose of this paper is to illustrate how Six Sigma methodology has been applied in a small-scale foundry industry to improve the overall first-pass material yield and quality, with a view to the product and the process. Design/methodology/approach The researchers have reported this paper based on a case study carried out in industry using the Six Sigma Define, Measure, Analyze, Improve and Control (DMAIC) and its application in improving the manufacturing process of a foundry shop. Findings Identified root causes are validated and countermeasures are implemented for improvement. As a result of this case study, the overall first-pass yield of the sand casting process is improved to 78.88% from the previous yield of 67%. For product-specific case, yield is improved by 18% through the improved gating system design. Sigma level of the process is improved to 3.08 from baseline 2.21. Key lessons learned from this case study are mentioned in the current study. Research limitations/implications This case study provides a standard road map and motivates small-scale foundry industries to implement Six Sigma methodology for productivity improvement, especially in jobbing foundry. The presented paper is based on a single case study, and the results are limited to the company only. Also, one of the reasons for low process yield is slag creation, which is not covered here, as it is a concern of the material quality supplied by the vendor. However, the approach of this paper is generic for learning perspective. Practical implications This case study provides a standard road map and motivates small-scale foundry industries to implement Six Sigma methodology for productivity improvement, especially in jobbing foundry. Through the effective application of Six Sigma quality initiative, how a quantum jump in financial aspect could be gain, has been demonstrated. Originality/value This research study showcases step-by-step implementation of Six Sigma-DMAIC methodology at a small-scale foundry industry. This paper could serve as a unique roadmap for practitioners and academicians to improve the material productivity of the foundry industry both ways, product and process.

Development of Six Sigma methodology to improve grinding processes

2018 ◽  
Vol 9 (1) ◽  
pp. 50-63 ◽  
Author(s):  
Behrooz Noori ◽  
Mana Latifi
Keyword(s):  
Change Management ◽  
Automotive Industry ◽  
Six Sigma ◽  
Grinding Process ◽  
Industrial Complex ◽  
Defect Reduction ◽  
Content Type ◽  
Six Sigma Methodology ◽  
Manufacturing Organization ◽  
Tools And Techniques

Purpose This paper aims to deploy the Six Sigma methodology to facilitate defect reduction and enhance the bottom-line results of an automotive industry. Design/methodology/approach Six Sigma is a business process improvement strategy widely used in manufacturing field for enhancing organizational performance. Six Sigma enables the attainment of defects reduction. In this study, the Six Sigma methodology has been developed with the integration of change management tools. Findings Six Sigma has been successfully implemented in the grinding process in automotive engine manufacturing organization. The proposed Six Sigma methodology has been applied to facilitate defect reduction. The developed methodology with linkage of DMAIC (define, measure, analyze, improve and control) and change management techniques reduces defects. Research limitations/implications The developed methodology has been implemented in an automotive industrial complex. In future, more number of studies could be conducted, i.e. for mistake proofing. Furthermore, advanced tools and techniques could be included in the methodology for increasing the effectiveness of change management. Practical implications The proposed Six Sigma methodology has been successfully implemented in a grinding process of automotive manufacturing organization; in future, the approach could be applied in different industrial sectors with addition of new tools and techniques for improving its effectiveness. Originality/value The Six Sigma methodology has been designed and implemented in the grinding process. Researchers have not treated Six Sigma in much detail in the automotive industry. Moreover, previous studies on Six Sigma have not dealt with the grinding process. Besides, most studies in the field of Six Sigma have focused only on DMAIC, but this study adds change management approach to DMAIC.

Lean Six Sigma in policing services

2018 ◽  
Vol 67 (5) ◽  
pp. 935-940 ◽  
Author(s):  
Jiju Antony ◽  
Bryan Rodgers ◽  
Inness Coull ◽  
Vijaya Sunder M.
Keyword(s):  
Six Sigma ◽  
Design Methodology ◽  
Single Case ◽  
Lean Six Sigma ◽  
Single Case Study ◽  
Content Type ◽  
The Public ◽  
Study Approach ◽  
Learning Points

Purpose This paper is based on a single case study carried out as part of a change programme but is used as a reflective tool to draw on some of the wider organisational learning which can be considered when implementing, reviewing or re-energise a Lean Six Sigma (LSS) Programme. The paper aims to discuss this issue. Design/methodology/approach A case study approach has been used and referenced throughout the paper with references to literature to support the wider learning points drawn which are then applied to any continuous improvement (CI) programmes. Findings The paper presents a range of learning points which are drawn from a successful deployment of LSS within a change project carried out as part of an overall programme in Scottish policing services. Research limitations/implications The points are drawn from a single case study which was deployed within a wider change programme and is supported by wider literature but is used as a vehicle for informing strategic considerations within an organisation. Originality/value This case study is drawn from policing services in the public sector which alone is an area that has not been significantly studied. It is used to explore wider implications in terms of strategic alignment, organisational performance and project management and presents the argument that the design of a CI programme is much wider than the implementation of LSS itself.

Application of Lean Six Sigma in conservative dentistry: an action research at an Indian dental college

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ajay Noronha ◽  
Shreeranga Bhat ◽  
E.V. Gijo ◽  
Jiju Antony ◽  
Suma Bhat
Keyword(s):  
Action Research ◽  
Six Sigma ◽  
Single Case ◽  
Lean Six Sigma ◽  
Lessons Learned ◽  
Healthcare Sector ◽  
Content Type ◽  
Conservative Dentistry ◽  
Tools And Techniques

PurposeThe article evaluates the obstacles, lessons learned and managerial implications of deploying Lean Six Sigma (LSS) in a dental college hospital in India.Design/methodology/approachThe work adopts the action research (AR) methodology to establish a case study, which is carried out using the LSS define–measure–analyze–improve–control (DAMIC) approach in a dental college. It uses LSS tools to enhance the productivity and performance of the Conservative Dentistry Department of a dental college and to unravel the obstacles and success factors in applying it to the education and healthcare sector together.FindingsThe root cause for high turn-around time (TAT) is ascertained using LSS tools and techniques. The effective deployment of the solutions to the root causes of variation assists the dental college to reduce the TAT of the Conservative Dentistry process from an average of 63.9 min–36.5 min (i.e. 42.9% improvement), and the process Standard Deviation (SD) was reduced from 2.63 to 2 min. This, in turn, raises the sigma level from 0.48 to 3.23, a noteworthy successful story for this dental college.Research limitations/implicationsWhile the results and recommendations of this research are focused on a single case study, it is to be noted that the case study is carried out with new users of LSS tools and techniques, especially with the assistance of interns. This indicates the applicability of LSS in dental colleges; thus, the adopted modality can be further refined to fit India's education and hospital sector together.Originality/valueThis article explains the implementation of LSS from an aspiring user viewpoint to assist dental colleges and policymakers in improving competitiveness. In addition, the medical education sector can introduce an LSS course in the existing programme to leverage the potential of this methodology to bring synergy and collaborative research between data-based thinking and the medical field based on the findings of this study. The most important contribution of this article is the illustration of the design of experiments (DOE) in the dental college process.

Process mining and lean six sigma: a novel approach to analyze the supply chain quality of a hospital

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Francisco Ramires ◽  
Paulo Sampaio
Keyword(s):  
Health Care ◽  
Supply Chain ◽  
Six Sigma ◽  
Process Mining ◽  
Lean Six Sigma ◽  
Content Type ◽  
Study Approach ◽  
Novel Approach

PurposeThis paper aims to depict the practical execution of the problem-solving structure provided by the define, measure, analyze, improve and control (DMAIC) framework in combination with the analytical power provided by process mining capabilities, to improve the supply chain quality of a health-care provider. Design/methodology/approachPrior to the study, a literature review was conducted to identify existing frameworks combining six sigma with process mining. The authors use a descriptive case study approach to explain how the two methodologies blend across the different phases of DMAIC in a health-care setting. FindingsThis case study describes how analyzing data extracted from core information systems has significant value to improvement initiatives when complemented by traditional quality methods. By intersecting process mining techniques with lean six sigma tools, the researchers found 65% of orders not complying with the target ordering time and 200 redundant purchases with high operational costs. Research limitations/implicationsBy depicting how the two methodologies can be intertwined, this paper complements existing research by presenting it as a viable quality improvement approach. Practical implicationsThis paper provides insights for six sigma and process mining practitioners on the benefits of combining both methodologies within the DMAIC structure. Implementing this blended approach can bring visibility to operations and accelerate process improvement initiatives. Originality/valueThe prime value of this paper lies in the integration of traditional six sigma methods with process mining as a technological approach in a health-care context, going beyond existing research, which, to the best of the knowledge, lacks descriptive case studies.

Performance and service quality enhancement in a healthcare setting through lean six sigma strategy

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Ajay Noronha ◽  
Shreeranga Bhat ◽  
E.V. Gijo ◽  
Jiju Antony ◽  
Alessandro Laureani ◽  
...  
Keyword(s):  
Service Quality ◽  
Six Sigma ◽  
Processing Time ◽  
College Education ◽  
Healthcare Setting ◽  
Lean Six Sigma ◽  
Content Type ◽  
Sustainable Solutions ◽  
Tools And Techniques

PurposeThe article intended to excavate the Lean Six Sigma (LSS) deployment challenges, Critical Success Factors (CSF), tools and techniques, and managerial implications in an Indian healthcare setting.Design/methodology/approachThe article illustrates a case study established using Action Research (AR) approach. Further, the case study is based on the Define, Measure, Analyze, Improve, Control (DMAIC) phases of LSS. The performance and service quality of the Endodontics department of a dental college attached to a hospital is enhanced and sustained through the LSS strategy.FindingsThe processing time of Root Canal treatment is reduced by determining the root causes for delay and implementing sustainable solutions. The structured deployment of the LSS strategy helped the Endodontics department to reduce the processing time from an average of 116 min–84 min. Thus, the process's sigma level is enhanced from 0.06 to 4.17 and assisted in sustaining the results.Research limitations/implicationsThe case study's findings are based on the single AR carried out at an Endodontics department of a dental college hospital based on LSS strategies. Even though this study's results cannot be generalized, the deliverables of the case study can be used to develop the LSS roadmap for the dental colleges to enhance the service quality and safety of the patients.Originality/valueThe article provides step-by-step details for implementing LSS in dental college hospitals with critical analysis based on robust statistical tools and techniques. The case study provides evidence of the adoption of LSS in medical college education and provides the confidence to adopt the same through novice users. The study's findings may persuade the policymakers to add LSS in the medical education curriculum to reinforce safety and reduce errors in the healthcare system.

Six Sigma for improving cash flow deficit: a case study in the food can manufacturing industry

2020 ◽  
Vol 11 (6) ◽  
pp. 1119-1140 ◽  
Author(s):  
Maria-Victòria Sánchez-Rebull ◽  
Ramon Ferrer-Rullan ◽  
Ana-Beatriz Hernández-Lara ◽  
Angels Niñerola
Keyword(s):  
Cash Flow ◽  
Six Sigma ◽  
Bargaining Power ◽  
Qualitative Methodology ◽  
Manufacturing Industry ◽  
Case Study Research ◽  
Control Process ◽  
Content Type ◽  
Six Sigma Methodology

Purpose Cash flow deficit situations and working capital control are major challenges for many companies, especially those whose suppliers and clients have strong bargaining power. This study aims to describe the application of the Six Sigma methodology for solving these problems in a large German food can manufacturing company. Design/methodology/approach This paper follows the qualitative methodology of case study research. During different define, measure, analyse, improve and control process phases, the problem and critical aspects are identified to improve the quality of the payment process and improvements are suggested and implemented. Findings The results provide evidence of how Six Sigma can be useful in administrative–financial processes that are carried out within a company. This result is particularly interesting because it is about processes that have not applied Six Sigma methodology. For the company studied, this methodology has balanced its cash flow and this meant large amounts of savings, especially in bank interest to avoid having to ask for bank credits. Originality/value This case can be extrapolated to other companies, regardless of the company size, that present similar symptoms of cash deficit, especially if their bargaining power with suppliers and customers is low.

Developing a model for process improvement using multiple regression technique

2014 ◽  
Vol 26 (6) ◽  
pp. 625-638 ◽  
Author(s):  
Ashok Sarkar ◽  
Arup Ranjan Mukhopadhyay ◽  
Sadhan Kumar Ghosh
Keyword(s):  
Multiple Regression ◽  
Six Sigma ◽  
Model Development ◽  
Real Life ◽  
Analytical Techniques ◽  
Lean Six Sigma ◽  
Process Efficiency ◽  
Content Type ◽  
Study Approach

Purpose – Practitioners often face challenges in model development when establishing a relationship between the input and output variables and their optimization and control. The purpose of this paper is to demonstrate, with the help of a real life case example, the procedure for model development between a key process output variable, called the multi-stage flash evaporator efficiency, and the associated input process variables and their optimization using appropriate statistical and analytical techniques. Design/methodology/approach – This paper uses a case study approach showing how multiple regression methodology has been put into practice. The case study was executed in a leading Indian viscose fiber plant. Findings – The desired settings of the relevant process parameters for achieving improved efficiency have been established by appropriately using the tools and techniques from the Lean Six Sigma tool kit. The process efficiency, as measured by M3 of water evaporated per ton of steam, has improved from 3.28 to 3.48 resulting in satisfactory performance. Originality/value – This paper will be valuable to many practitioners of Six Sigma/Lean Six Sigma and researchers in terms of understanding the systematic application of quality and optimization tools in a real world situation.

Application of Six Sigma methodology in a small-scale foundry industry

2014 ◽  
Vol 5 (2) ◽  
pp. 193-211 ◽  
Author(s):  
E.V. Gijo ◽  
Shreeranga Bhat ◽  
N.A. Jnanesh
Keyword(s):  
Six Sigma ◽  
Single Case ◽  
Leaf Spring ◽  
Small Scale ◽  
Content Type ◽  
Foundry Industry ◽  
Small Scale Industry ◽  
Six Sigma Methodology ◽  
Finance Department

Purpose – The purpose of this article is to illustrate how the Six Sigma methodology was applied to a small-scale foundry industry to reduce the rejections and rework in one of its processes. Design/methodology/approach – The research reported in this paper is based on a case study carried out in an industry using the Six Sigma Define-Measure-Analyze-Improve-Control (DMAIC) approach and its application in improving the leaf spring manufacturing process of a foundry shop. Findings – The root causes for the problem of rejection and rework were identified through data-based analysis at different stages in the project. The process parameters were optimized and measures for sustainability of the results were incorporated in the process. As a result of this study, the overall rejection was reduced from 48.33 to 0.79 per cent, which was a remarkable achievement for this small-scale industry. This was leading to improvement in on-time delivery to the customer. The finance department of the company estimated the annualized savings due to the reduction in rejection and was to the tune of USD8,000 per year. Research limitations/implications – The paper is based on a single case study executed in a company, and hence, there is limitation in generalizing the specific results from the study. However, the approach adopted and the learning from this study can be generalized. Originality/value – This article illustrates the step-by-step application of Six Sigma DMAIC methodology in a small-scale foundry industry to solve an age-old problem in the organization. Thus, this article will be helpful for those professionals who are interested in implementing Six Sigma to such industries.

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