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.

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.

scholarly journals Defects analysis of frozen fish steak processing using six sigma: a case study

2021 ◽  
Vol 919 (1) ◽  
pp. 012038
Author(s):  
A Poernomo ◽  
N Ferawati ◽  
R B S Salampessy
Keyword(s):  
Six Sigma ◽  
Sigma Level ◽  
Frozen Fish ◽  
Defects Analysis ◽  
Green Coloration

Abstract Six Sigma has been utilised to analyse defects of fish steak processing at PT X located in North Jakarta. The tools of the Six Sigma implemented in the study were Define, Measure, Analyse and Improve. The observation was conducted for two months in 2020 before the company was temporarily shut down due to Covid-19 pandemic. Four defects were detected during the study, ie under size fish, softened meat, off odor and green coloration of meat, totaling 2,446 kg out of 15,080 kg of fish. Further analysis showed that the Sigma level was 3.24 with a Defect per Million Opportunities (DPMO) of 40,739. Some improvements were recommended based on cause-effect diagram.

scholarly journals Six Sigma in Urban Logistics Management—A Case Study

2021 ◽  
Vol 13 (8) ◽  
pp. 4302
Author(s):  
Justyna Lemke ◽  
Kinga Kijewska ◽  
Stanisław Iwan ◽  
Tomasz Dudek
Keyword(s):  
Six Sigma ◽  
Production Systems ◽  
Root Cause ◽  
Sigma Level ◽  
Last Mile ◽  
Completion Process ◽  
Transfer Services ◽  
Last Mile Delivery

A city as a system that constitutes one of the most important areas of human activities. The significant role to fulfill their expectations pay the goods transport and deliveries. These issues are the subject of urban logistics. In broad terms, urban logistics may be construed as a number of processes focused on freight flows, which are completed in cities, including deliveries, supply, goods transfer, services, etc. Due to the different urban logistics stakeholders’ expectations, these systems generate many challenges for managers, especially in the context of city users’ needs and their quality of life. Today, there is a lack of broadened approach and methodology to support them from the processes’ efficiency perspective. To fulfill this gap, the purpose of this paper is to apply the Six Sigma method as a support in last mile delivery management. Six Sigma method plays important role in production systems processes management. However, it could be useful in much wider perspective, including transport and logistics processes. The Authors emphasize that the Six Sigma method could be efficient approach in the last mile delivery processes’ analysis in the context of their efficiency. It helps positioning the customer satisfaction level and quantify the delivery processes defects, related to the undelivered goods. Following that it could improve significantly the last mile delivery processes efficiency. The concept is illustrated by a sample evaluation of one of the urban logistics processes: completion of deliveries. To this end, urban logistics processes were defined. In particular, the delivery completion process was mapped, and the process client was defined along with their expectations. The defects that occurred in the process were identified and analyzed. A DPMO (Defect per Million Opportunities) indicator was established for three randomly selected months. In addition, a root cause analysis of errors was performed. The sigma level for the studied process ranged from 2.61 to 2.89. The factor that had the greatest impact on the number of defects defined as failed deliveries was customer’s absence. The obtained results indicate that the delivery process should be examined in more detail.

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.

Development and validation of DMAIC based framework for process improvement: a case study of Indian manufacturing organization

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Pramod Kumar ◽  
Dharmendra Singh ◽  
Jaiprakash Bhamu
Keyword(s):  
Cost Savings ◽  
Lean Six Sigma ◽  
Successful Implementation ◽  
Extensive Literature ◽  
Content Type ◽  
Implementation Phase ◽  
Sigma Level ◽  
Manufacturing Organization ◽  
Case Organization

PurposeThe purpose of this paper is to develop and validate an extended Define-Measure-Analyze-Improve-Control (DMAIC) based framework through a case study of an Indian fasteners manufacturing organization.Design/methodology/approachResearch methodology is established on the development of the existing DMAIC framework through an extensive literature review of 25 LSS/DMAIC based frameworks and discussions held with practitioners. This paper also depicts a case study of Indian manufacturing organization for validation of the developed framework.FindingsThe study proposed an extended DMAIC based framework for effective implementation of Lean Six Sigma (LSS) methodology. Furthermore, this framework has been implemented successfully in the Indian manufacturing organization and showed encouraging results. The in-house rejections of Nut Cylinder Head (NCH) were brought down to 966 from 2910 PPM and sigma level was improved by 0.40. The case organization has achieved significant improvements in the process capability, customer satisfaction, and cost savings of US$ 0.25 million in one financial year. Intangible benefits like improvements in employee's morale, communication, housekeeping and decision-making capabilities were also observed significantly.Practical implicationsThe proposed DMAIC based framework has been implemented successfully in the Indian case organization, and the results will enable the policymakers, specifically practitioners, to strategically leverage the resources for successful implementation of the LSS in healthcare, aerospace, service sectors etc.Originality/valueThis research develops a DMAIC based framework which can be used to implement LSS effectively in different industries. Moreover, the pre (initial/introduction) and post (validation/verification) implementation phase provides the top management, an edge to think strategically into broader improvement areas.

Enhancement of sigma level in the manufacturing of furnace nozzle through DMAIC approach of Six Sigma: a case study

2016 ◽  
Vol 27 (10) ◽  
pp. 810-822 ◽  
Author(s):  
K. Srinivasan ◽  
S. Muthu ◽  
S. R. Devadasan ◽  
C. Sugumaran
Keyword(s):  
Six Sigma ◽  
Sigma Level

scholarly journals Application of Six Sigma (Dmaic) Method to Reduce Defect Amount in Assembly Process A Case Study PT. XYZ

2019 ◽  
Vol 2 (3) ◽  
pp. 59
Author(s):  
Warinah Warinah ◽  
Dewi Nusraningrum
Keyword(s):  
Six Sigma ◽  
Assembly Process ◽  
Sigma Level ◽  
Heel Height ◽  
A Company ◽  
Dmaic Method ◽  
Improvement Effort ◽  
Very High ◽  
Method Show

PT. XYZ is a company engaged in industry and manufacturing in the manufacture of sports shoe products. The company has a very high defect in the assembly process seen in the defective rate report from January 2017 to August 2018. The purpose of this study is to reduce the number of defects in the assembly process using the Six Sigma (DMAIC) method. The results showed that there were 5 dominant types of defects related to Critical To Quality (CTQ), namely Undercement, Dirty shoes, Unpairing-heel height, Broken stitching and Quarter wrinkles. Furthermore, an analysis of the causes of defects is carried out by using cause and effect diagrams and an improvement effort using 5W + H analysis. The results of efforts to decrease the number of defects in the assembly process using the DMAIC method show that the DPMO value for these five CTQ defects decreased to 2056 PPM from 3898 PPM or decreased by 47.3%. Whereas for the value of the sigma level obtained 4.39 σ from 4.16 σ

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