Reduction of rework the Six Sigma way: case study of an Indian small scale industry

2012 ◽  
Vol 7 (1) ◽  
pp. 92 ◽  
Author(s):  
Prasenjeet C. Gholap ◽  
Tushar N. Desai
Keyword(s):  
Six Sigma ◽  
Small Scale ◽  
Small Scale Industry

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.

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.

Implementing a Lean Six Sigma standardized toolset in a manufacturing company: a case study

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Nikolaos A. Panayiotou ◽  
Konstantinos E. Stergiou ◽  
Vassilis Chronopoulos
Keyword(s):  
Case Studies ◽  
Six Sigma ◽  
Success Factors ◽  
Manufacturing Sector ◽  
Lean Six Sigma ◽  
Small Scale ◽  
Manufacturing Companies ◽  
Content Type ◽  
Manufacturing Company

PurposeThe first purpose of this paper is the implementation of Lean Six Sigma (LSS) in a manufacturing company operating in South East Europe in order to understand the importance of critical success factors (CSFs) in LSS adoption and to find out the benefits that the company gained. The second purpose is to propose a standardized toolset based on DMAIC phases, for the application of LSS in small scale projects, in order to facilitate LSS adoption by more manufacturing companies.Design/methodology/approachThis case study is based on the interlacement of the Yin's method about case studies and the DMAIC method for the improved deployment of LSS.FindingsThe analysis of this case study shows that the company attained to benefit financially, operationally and organizationally from the implementation of LSS. The already existing mentality of CI inside the company helped the project procedure and the application of changes and improvements fulfilling LSS adoption CSFs.Practical implicationsThe paper constructs a toolset and studies the role of CSFs in order to achieve the desirable benefits in a manufacturing environment, constituting a guide for future LSS initiatives.Originality/valueAs stated by literature reviews, even though there are several papers concerning LSS implementation in the manufacturing sector, there is a need for more case studies papers, such as this one, in order to enrich the literature. In this paper, it is also the first time that a specific toolset for small scale projects is proposed based on to DMAIC which can be implemented in further LSS projects.

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