An application of Six Sigma methodology to reduce the engine-overheating problem in an automotive company

2005 ◽  
Vol 219 (8) ◽  
pp. 633-646 ◽  
Author(s):  
J Antony ◽  
M Kumar ◽  
M K Tiwari
Keyword(s):  
Six Sigma ◽  
Continuous Process ◽  
Quality Level ◽  
Bottom Line ◽  
Control Approach ◽  
Defect Rate ◽  
Automotive Company ◽  
Six Sigma Methodology ◽  
Operational Excellence ◽  
Unrealistic Expectations

Six Sigma is a systematic methodology for continuous process quality improvement and for achieving operational excellence. The overstatement that often accompanies the presentation and adoption of Six Sigma in industry can lead to unrealistic expectations as to what Six Sigma is truly capable of achieving. This paper deals with the application of Six Sigma based methodology in eliminating an engine-overheating problem in an automotive company. The DMAIC (define-measure-analyse-improve-control) approach has been followed here to solve an underlying problem of reducing process variation and the associated high defect rate. This paper explores how a foundry can use a systematic and disciplined approach to move towards the goal of Six Sigma quality level. The application of the Six Sigma methodology resulted in a reduction in the jamming problem encountered in the cylinder head and increased the process capability from 0.49 to 1.28. The application of DMAIC has had a significant financial impact (saving over $US110 000 per annum.) on the bottom-line of the company.

scholarly journals STUDY OF FEASIBILITY OF SIX SIGMA IMPLEMENTATION IN A MANUFACTURING INDUSTRY : A CASE STUDY

2014 ◽  
pp. 296-300
Author(s):  
MEHDIUZ ZAMAN ◽  
SUJIT KUMAR PATTANAYAK ◽  
ARUN CHANDRA PAUL
Keyword(s):  
Six Sigma ◽  
Capital Investment ◽  
Manufacturing Industry ◽  
Study Data ◽  
Quality Level ◽  
Control Approach ◽  
Sigma Level ◽  
Six Sigma Methodology ◽  
Welding Electrode

This paper discusses the implementation of Six-sigma methodology in reducing rejection in a welding electrode manufacturing industry. The Six-sigma DMAIC (define– measure – analyse –improve – control) approach has been used to achieve this result. This paper explains the step-by-step approach of Six-sigma implementation in this manufacturing process for improving quality level. This resulted in reduction of rejection, and thus, reduced the Defect Per Million Output (DPMO) from 28356.96 to 1666.67. This had resulted in increasing the sigma level from 3.41 to 4.43, without any huge capital investment. During this study, data were collected on all possible causes and was analysed and thereby conclusions were made. Implementation of Six-sigma methodology has resulted in large financial savings for the industry.

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 for improving aesthetic defects in aluminum profiles facility

Facilities ◽  
2017 ◽  
Vol 35 (3/4) ◽  
pp. 242-267 ◽  
Author(s):  
Laith A. Hadidi ◽  
Abdulaziz Bubshait ◽  
Suleiman Khreishi
Keyword(s):  
Six Sigma ◽  
Control Charts ◽  
Field Work ◽  
Facility Management ◽  
Quality Level ◽  
Content Type ◽  
Fabrication Defects ◽  
Six Sigma Methodology ◽  
Chemical Imbalance ◽  
Aluminum Profiles

Purpose This paper aims to develop a quality plan to detect aesthetic defects in extruded aluminum profiles before the fabrication stage based on the Six Sigma improvement methodology in an aluminum facility. These defects are hard to be detected at the fabrication stage. It is also hard to be fixed in the site. Design/methodology/approach The research methodology utilized the DMAIC framework (define, measure, analyze, improve and control). The methodology relies on statistical analysis (histogram, control charts and Pareto) and field work (observations, focus groups and interviews). Findings The process shows significant improvement in aesthetic defect reduction that aids in reaching a Four Sigma quality level. Practical implications Aluminum fabrication is known to be vulnerable for many types of defects such as scratches and debris on work surface. In addition, post-fabrication defects may also occur due to improper coating caused by chemical imbalance, blocked filters or blocked sprays. Originality/value The main contribution of this research is to demonstrate the use of DMAIC framework to reduce the aluminum aesthetic defects that reach the end customer. The Six Sigma methodology is a well-known quality improvement framework that relies heavily on quantitative data. More precisely, it is widely used to control defects in quantities such as weights, heights, etc. In this research, it has been used to control qualitative data (aesthetic). This will enable objective decisions for facility management rather than subjective.

scholarly journals Six Sigma Implementation Efficiency in an Automobile Firm

2019 ◽  
Vol 8 (4) ◽  
pp. 12125-12129
Keyword(s):  
Six Sigma ◽  
Continuous Process ◽  
Quality Level ◽  
Manufacturing Strategy ◽  
New Paradigm ◽  
Research Activity ◽  
Productivity Improvement ◽  
Effect Analysis ◽  
Pareto Analysis ◽  
Study Results

Six Sigma a new paradigm and fast growing manufacturing strategy executed and streamlined across recent automobile firms. This methodology have been faster pace of growth worldwide which helps to enhance productivity and quality improvement on existing process robust to monitor quality variations across manufacturing firms. To respond to quality changes happening every firm within the industry aligning themselves to show continuous process changes by building their existing infrastructure through Kaizen, JIT manufacturing, Business Process Reengineering practices to attain global competitive advantage and also to meet changing global customer demands by providing high quality products. This study results discussed six sigma implementation practices and various defects analysis methods followed in an automobile firm for quality and productivity improvement. This study used systematic literature review approach by analyzing existing major defective parts from the overall manufacturing products of the firm and has been analyzed using quality tools like Pareto analysis, Cause and Effect Analysis, 5 - Why analysis and Scatter diagram. The findings from this study definitely allow future researchers to progress their research activity in this field of activity helps them to open up new opportunities on six implementation issues to develop and evolve. Overall this study concluded with the suggestion of implementing Six Sigma DMAIC (Define–Measure-Analyze-Improve-Control) methodology which provides a framework to identify, quantify and eliminate sources of variation by optimizing operation variables which helps the firm to improve and sustain performance. The motive of this study is to achieve higher quality level for mutual benefits of organization and customer

scholarly journals Six sigma application for raising student academic achievement

2021 ◽  
pp. 699-710 ◽  
Author(s):  
Mazen Arafeh ◽  
Mais Khader ◽  
Tamer F. Desouky ◽  
Nour Azzam ◽  
Aishah Aljundi
Keyword(s):  
Academic Achievement ◽  
Student Performance ◽  
Six Sigma ◽  
School Administrators ◽  
Student Academic Achievement ◽  
Quality Level ◽  
Fishbone Diagram ◽  
Six Sigma Methodology ◽  
Arabic And English ◽  
Student Grades

This paper presents a case study on how Six Sigma methodology can be used to improve student academic performance in three main subjects (Math, Arabic, and English) in a private secondary school located in the Middle East. The Six Sigma methodology of Define, Measure, Analyze, Improve and Control (DMAIC) was used to improve student performance along with several improvement tools such as Fishbone diagram, Pareto charts, and Critical-To-Quality (CTQ) tree. Introducing quality improvement concepts and tools resulted in a series of improvements leading to an increase in student academic achievement quantified by Sigma Quality Level (SQL). The SQL improved in Math from (2.01) to (2.37) and in Arabic from (1.86) to (2.38). On the other hand, English grades did not increase from baseline. The results of this study provide a clear, step-by-step approach to systematically approaching and solving educational problems using the DMAIC model. Practically speaking, the results of this study provides clear evidence that the DMAIC can be used in the educational sector by school administrators and teachers to improve student grades.

Contactless Chip Module Defect Reduction

2020 ◽  
Vol 305 ◽  
pp. 59-64
Author(s):  
Thunwarat Sawatsuphaphon ◽  
Parames Chutima
Keyword(s):  
Integrated Circuits ◽  
Six Sigma ◽  
Defect Reduction ◽  
Root Cause ◽  
Defect Rate ◽  
Manufacturing Company ◽  
Six Sigma Methodology

This research was conducted in a manufacturing company that produces integrated circuits for global customers. The purpose of this research was to reduce defect rate from the assembly department that affected to product lots on hold at the test department for the contactless chip module package which had an increasing product lots on hold rate of 9.5% in March 2019 based on the reject criteria V_limiter (REQA). The potential cause of defect came from die crack. In order to reduce defect rate, the 5 steps of DMAIC Six Sigma methodology were applied in this research to identify the root cause of the problem and establish effective actions. After the improvement, the product (lots) on hold criteria V_limiter (REQA) was reduced from 9.5% to 5.82% in July 2019.

Defects Reduction in Steering Gear Product Using Six Sigma Methodology

2014 ◽  
Vol 598 ◽  
pp. 647-651
Author(s):  
Ganesh Kumar Nithyanandam ◽  
Manmohanraj Raju ◽  
Gokulraj Srinivasan
Keyword(s):  
Six Sigma ◽  
South India ◽  
Lean Six Sigma ◽  
Quality Level ◽  
Systematic Methodology ◽  
Data Driven Approach ◽  
World Class ◽  
Component Manufacturing ◽  
Six Sigma Methodology ◽  
Product Defect

Lean Six Sigma is a disciplined data driven approach to improve the quality and the performance of a process or a system with which finally results to the profitability of a firm. Many of the organizations have adopted Six Sigma methodology to improve their quality and their performance to competitive industrial world. This work is concentrated with one of the leading Automotive component manufacturing company in South India. The main objective of this paper was to reduce the product defect with the application of Lean Six Sigma methodology. The paper follows the DMAIC methodology to investigate defects and its root causes and provide a solution to reduce and/or eliminate these defects. This paper also explores how a manufacturing process can use a systematic methodology to move towards world-class quality level.

Application of Lean Six Sigma methodology in the registration process of a hospital

2014 ◽  
Vol 63 (5) ◽  
pp. 613-643 ◽  
Author(s):  
Shreeranga Bhat ◽  
E.V. Gijo ◽  
N.A. Jnanesh
Keyword(s):  
Six Sigma ◽  
Single Case ◽  
Lean Six Sigma ◽  
Healthcare Sector ◽  
College Hospital ◽  
Content Type ◽  
Control Approach ◽  
Registration Process ◽  
Six Sigma Methodology

Purpose – The purpose of this paper is to study the scope of Lean Six Sigma (LSS) strategy and to explore its successful deployment in the Indian healthcare sector. Design/methodology/approach – The research reported in this paper is based on a case study carried out using the LSS DMAIC (Define-Measure-Analyze-Control) approach and its application in improving the registration process in the Health Information Department (HID) of a Medical College hospital in India. Findings – The study describes improvements in the HID through the power of LSS. Cycle time of the process was reduced from three to 1.5 minutes and the SD was reduced to 21.2 from 61 seconds. The project has shown a 94 per cent reduction in patients’ average waiting time. The study also reported a 91 per cent reduction in queue length and 48 per cent reduction in percentage of scheduled utilization of staff for the process. Research limitations/implications – The paper is based on a single case study executed in a hospital and hence there is limitation in generalizing the specific results from the study. But the approach adopted and the learning from this study can be generalized. The study is of use to healthcare practitioners seeking to implement or develop LSS further in their organizations. Originality/value – Although LSS being extremely successful in the last two decades, the application of LSS to the healthcare industry in general and HID in particular has been limited. This study illustrates how its application can improve the performance of the process and thus productivity in the department.

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