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

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.

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Measure and Analyze the Problems of Concrete Mixture Production via Six Sigma DMAIC Tools: Central Concrete Mix Plant as a Case Study

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.622-623.472 ◽

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.

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Reducing failure rate at high voltage (HV) testing of insulator using Six Sigma methodology

International Journal of Productivity and Performance Management ◽

10.1108/ijppm-11-2016-0235 ◽

2018 ◽

Vol 67 (5) ◽

pp. 791-808 ◽

Cited By ~ 3

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.

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Six Sigma methodology for reducing defects in manufacturing industry - a case study

International Journal of Indian Culture and Business Management ◽

10.1504/ijicbm.2017.10008545 ◽

2017 ◽

Vol 15 (4) ◽

pp. 397

Author(s):

Deepinder Singh ◽

Virender Singh ◽

Harwinder Singh ◽

Jagdeep Singh

Keyword(s):

Six Sigma ◽

Manufacturing Industry ◽

Six Sigma Methodology

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

Journal of Advances in Management Research ◽

10.1108/jamr-11-2018-0102 ◽

2019 ◽

Vol 16 (4) ◽

pp. 594-624 ◽

Cited By ~ 1

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.

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

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1243/095440505x32418 ◽

2005 ◽

Vol 219 (8) ◽

pp. 633-646 ◽

Cited By ~ 38

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.

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

International Journal of Lean Six Sigma ◽

10.1108/ijlss-12-2018-0137 ◽

2020 ◽

Vol 11 (6) ◽

pp. 1119-1140 ◽

Cited By ~ 1

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.

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Six Sigma methodology for reducing defects in manufacturing industry - a case study

International Journal of Indian Culture and Business Management ◽

10.1504/ijicbm.2017.087628 ◽

2017 ◽

Vol 15 (4) ◽

pp. 397

Author(s):

Jagdeep Singh ◽

Harwinder Singh ◽

Deepinder Singh ◽

Virender Singh

Keyword(s):

Six Sigma ◽

Manufacturing Industry ◽

Six Sigma Methodology

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

International Journal of Productivity and Performance Management ◽

10.1108/ijppm-11-2013-0191 ◽

2014 ◽

Vol 63 (5) ◽

pp. 613-643 ◽

Cited By ~ 72

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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Six Sigma Methodologies and its Application in Manufacturing Firms

International Journal of Engineering and Management Research ◽

10.31033/ijemr.11.4.10 ◽

2021 ◽

Vol 11 (4) ◽

Author(s):

Mudit M. Saxena

Keyword(s):

Leadership Styles ◽

Process Improvement ◽

Six Sigma ◽

Manufacturing Industry ◽

Process Management ◽

Main Principle ◽

Main Aspect ◽

Statistical Concept ◽

Sigma Level ◽

Six Sigma Methodology

Six Sigma is a methodology for process improvement as well as a statistical concept that looks for to determine the variation intrinsic in any process. Six Sigma represents process, that is having 3.4 defects per million opportunities. i.e. 99.99966 % of the products from a Six Sigma process are perfect. Firms can impact their sigma level by combining main principles from the Six Sigma methodology into leadership styles, process management, and improvement activities. Main principle of the technique is a focus on the customer. There are many challenges in the implementation of Six Sigma. A well-run manufacturing team can make the entire firm more successful through cost-saving measures, increased quality and a larger inventory of products that the company can market. The Six Sigma objective is to make sure the process has minimum defects(3.4 defects per million chances). Every aspect of the process must be carefully planned and documented in detail in order for manufacturing to go efficiently. The main aspect of Six Sigma for enhancement in the manufacturing industry is to maximize the financial returns.

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