Dinesh Khanduja - Academia.edu (original) (raw)

Papers by Dinesh Khanduja

Research paper thumbnail of Six Sigma Methodology and Implementation in Indian Context: A Review-Based Study

Six Sigma is a highly disciplined approach used to reduce process variation and improve quality b... more Six Sigma is a highly disciplined approach used to reduce process variation and improve quality by analyzing the recorded data thoroughly using statistical tools. In recent years, the implementation of the Six Sigma strategy got a substantial hike in every business sector like manufacturing, service, and process across the world. But Indian industrial practitioners are still oblivious about the efficacy of Six Sigma as compared to the worldwide exploration of this approach. So this is the prime time to make aware of them about Six Sigma approach and its implementation. The focus of the present paper is the illustration of the basic concept, industrial methodology, tools, and effective employment of Six Sigma in India so that any industrial practitioner may easily understand Six Sigma concept, methodology, and toolset available for continuous improvement. Moreover, the future research direction is described in the field of Six Sigma.

Research paper thumbnail of Maintenance Priorities for a Repairable System of a Thermal Power Plant Subject to Availability Constraint

International journal of performability engineering, Nov 1, 2016

Research paper thumbnail of A case study

The TQM Journal, Jan 6, 2012

PurposeSix Sigma within small and medium‐sized enterprises (SMEs) is rapidly emerging as the new ... more PurposeSix Sigma within small and medium‐sized enterprises (SMEs) is rapidly emerging as the new wave of change in Six Sigma. The purpose of this paper is to review the implications of applying Six Sigma methodology over the SMEs, taking a specific case of a bicycle chain manufacturing unit. The study could be a paradigm initiative towards high quality products and services at low cost for every SME.Design/methodology/approachBased on the literature, this paper proposes a process flow chart to present a one‐shot picture of the Six Sigma application in a bicycle chain manufacturing unit which falls in an SME environment. The methodology adopted is DMAIC methodology of Six Sigma, which had been mostly successful so far in large‐scale industries. The methodology has been applied to reduce the bush rejection rate (bush is an important component of a cycle chain) by reducing defects inherent in the processes. The statistical techniques such as two sample t‐test and process capability analysis have been used to establish the process capability before and after the Six Sigma application.FindingsThis paper is an attempt to justify the highly useful role of quality management techniques like Six Sigma for SMEs which are normally presumed to be in the domain of large industries. In this paper, Six Sigma methodology has been applied to a small unit manufacturing bicycles chains with dwindling productivity levels. After applying Six Sigma it was found that the chain manufacturing firm can increase its profit by controlling high rejection rate of cycle chain bush. Application of Six Sigma project recommendation brought up the process sigma level to 5.46 from 1.40 by reduction in bush diameter variation in the process of bicycle chain bush manufacturing. This increase in sigma level is equivalent to monetary saving of Rs 0.288 million per annum, which is a noteworthy figure for an industry of such level. The success of this study paves the way to further extend the Six Sigma application to more such industries working in the SME environment.Originality/valueThis paper provides documented evidence of Six Sigma implementation in a bicycle chain manufacturing unit which has been taken as representative of a small and medium‐size industry. The study will yield a great value to academics, consultants, researchers and practitioners of Six Sigma.

Research paper thumbnail of Integrating Agile Thinking into Maintenance Strategy Performance Analysis

International Journal of Process Management and Benchmarking, 2018

Research paper thumbnail of Studies on induction hardening of powder-metallurgy-processed Fe–Cr/Mo alloys

International Journal of Minerals, Metallurgy, and Materials, 2017

Research paper thumbnail of Production of AA6082-Si3N4 /Gr Hybrid Composite by a Novel Process and Evaluation of its Physical Properties

i-manager's Journal on Material Science, 2015

Research paper thumbnail of AA6061/B4C/Graphite/CeO2 Reinforced Hybrid Composite Development and Evaluation of Its Properties

Social Science Research Network, 2017

Research paper thumbnail of Risk Analysis of Water Treatment Plant Using Fuzzy-Integrated Approach

Harmony Search and Nature Inspired Optimization Algorithms, 2018

The study addresses and expounds the identification and prioritization of various causes of failu... more The study addresses and expounds the identification and prioritization of various causes of failure in the water treatment plant of an organization. The water treatment plant was being studied under the guidance of plants management team and data was collected. For identification of various causes of failure, fishbone diagram or cause and effect method has been used. A total of 16 causes of failure have been identified as a potential risk. The failure mode and effect analysis FMEA and Fuzzy methodology has been used for the proposed study. For FMEA, risk priority number (RPN) is used to prioritize failure causes. The uncertainty due to imprecise and vague expert judgment has been removed using fuzzy methodology. If-then rules are made in fuzzy inference system (FIS), and fuzzy RPN (FRPN) is obtained as output. The outputs of both methods are compared to get correct analysis. The average FRPN is evaluated as 5.375, that indicated that 4 out of 16 failure causes are critical for the system and require immediate and stringent attention from the maintenance department. The iron membrane filter, media filter choke acid dosing, sand/multimedia filter are identified as prominent causes of failure. Finally, the present methodology, under multiple sources of different and uncertain evaluation information is used to assist maintenance personnel for proper maintenance planning, reducing risks, improving the efficiency of the system and reducing the cost of the installation in water treatment plant.

Research paper thumbnail of Cost of poor quality reduction in auto sector: an exploration with Six-Sigma

International Journal of Six Sigma and Competitive Advantage, 2021

Research paper thumbnail of Total Fuzzy Agility Evaluation Using Fuzzy Methodology: A Case Study

Harmony Search and Nature Inspired Optimization Algorithms, 2018

The present study evaluates the agility of a medium-scale industry in the northern state of India... more The present study evaluates the agility of a medium-scale industry in the northern state of India. For evaluating agility, a ‘Total Fuzzy Agility Index’ is defined, which serves as a benchmark for assessing two parameters, namely agility level and Total Fuzzy Performance-Importance Index (TFPII). TFPII forms a basis for identifying principle obstacles in the process of increasing agility level. Once identified, principle obstacles are ranked for exploring gaps. In the present study, 132 agile enablers have been identified and used for evaluation out of which 13 have been assessed as obstacles. This study will serve as a decision support system for managements to identify obstacles, rank, and correct them for increasing agility level of the organization. This research paper analyses these issues and concludes by suggesting a future roadmap for successful implementation of agile practices.

Research paper thumbnail of Prioritizing Autonomous Maintenance System Attributes using Fuzzy EDAS Approach

Procedia Computer Science, 2020

Research paper thumbnail of A study on implementation of lean manufacturing in Indian foundry industry by analysing lean waste issues

Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2016

Lean proliferates the value-adding work by eliminating wastes and reducing incidental and non-val... more Lean proliferates the value-adding work by eliminating wastes and reducing incidental and non-value-adding work to a certain possible extent. Waste can be defined as anything other than the essential resources of people, machines, and materials that are needed to add value to the product. According to the lean concept, any action which does not directly enhance product’s value can be considered as waste. Analysis of lean waste issues is one of the primary steps to implement lean principles in many industries and the same is applicable for the foundry industry as well. The purpose of this article is to investigate the importance of various lean waste issues in Indian foundry industry for improvement in productivity and elimination of wastes, thereby initiating lean implementation. For the purposes of this study, we employed the survey questionnaire method to collect data against 17 lean waste issues from 71 middle- to senior-level professionals belonging to Indian foundry industry. T...

Research paper thumbnail of An empirical study on applicability of lean and green practices in the foundry industry

Journal of Manufacturing Technology Management, 2016

Purpose – The purpose of this paper is to investigate the applicability of lean and green practic... more Purpose – The purpose of this paper is to investigate the applicability of lean and green practices to foundry industry in India for improving productivity and eliminating waste, incorporating the sustainability into business performance measures. Design/methodology/approach – The study used survey questionnaire method to collect data against 16 lean and green practices from 71 middle- to senior-level professionals belonging to Indian foundry industry. The survey instrument of lean and green practices was developed based on a number of sources from the literature and formal discussions with academicians and foundry industry professionals. The responses were received on a five-point Likert scale ranging from least applicable to most applicable. Exploratory factor and reliability analyses are conducted to obtain and validate constructs and measure each constructs Cronbach’s α (i.e. a consistency coefficient). The lean and green practices are categorized into the four constructs, namel...

Research paper thumbnail of Parametric Study of Dry Sliding Wear Behavior of Hybrid Metal Matrix Composite Produced by a Novel Process

Metallurgical and Materials Transactions A, 2015

Research paper thumbnail of A study on microstructure of aluminium matrix composites

Journal of Asian Ceramic Societies, 2015

Research paper thumbnail of Effect of graphite reinforcement on physical and mechanical properties of aluminum metal matrix composites

Particulate Science and Technology, 2015

ABSTRACT This work focuses on the effect of graphite particles addition on the properties of AA 6... more ABSTRACT This work focuses on the effect of graphite particles addition on the properties of AA 6082 metal matrix composites fabricated by conventional stir casting method. The percentage of reinforcement was varied from 0% to 12% in a step of 3%. The results revealed that with the addition of graphite particles the micro and macro-hardness decreased by 11.11% and 10.44% respectively. The ultimate tensile strength also decreased by 5.88% with a reduction in percentage elongation from 8.7 to 6.8. The density decreased by 4.1% with an increase in porosity from 0.37% to 2.27% as the weight percentage of graphite particles increased from 0% to 12%.

Research paper thumbnail of Computational Support to Design and Fabrication of Traditional Indian Jewelry

Research paper thumbnail of Metallurgical and mechanical characterization of electron beam welded DP600 steel joints

Journal of Materials Science, 2011

Research paper thumbnail of Enigma and Growth of Business Incubators In India

International Journal of …, 2008

Page 1. www.IndianJournals.com Members Copy, Not for Commercial Sale Downloaded From IP - 66.249.... more Page 1. www.IndianJournals.com Members Copy, Not for Commercial Sale Downloaded From IP - 66.249.67.66 on dated 10-Jul-2010 International Journal of Applied Engineering Research ISSN 0973-2683 Volume 3 Number 10 (2008) pp. ...

Research paper thumbnail of Tribological and mechanical behavior of particulate aluminum matrix composites

Journal of Reinforced Plastics and Composites, 2014

Aluminum and its alloy are light in weight, ductile, strong and long lasting, having high corrosi... more Aluminum and its alloy are light in weight, ductile, strong and long lasting, having high corrosion resistance, good conductor of heat and electricity and are 100% recyclable. Despite all these good qualities, it has low wear resistance. But some applications entail high hardness and tensile strength, high modulus of elasticity than the conventional aluminum alloy with good tribological properties. Keeping in view the enhancement of mechanical as well as tribological properties with reduction in weight, the aluminum alloy is reinforced with a second phase which is hard and brittle, and the newly formed material has better mechanical and tribological properties. The paper reviews the various manufacturing processes of aluminum matrix composites, and it was found that the mechanical and tribological properties of the single reinforcement composites are better as compared to pure aluminum and its alloys irrespective of the aluminum matrix composites manufacturing process. Further, it w...

Research paper thumbnail of Six Sigma Methodology and Implementation in Indian Context: A Review-Based Study

Six Sigma is a highly disciplined approach used to reduce process variation and improve quality b... more Six Sigma is a highly disciplined approach used to reduce process variation and improve quality by analyzing the recorded data thoroughly using statistical tools. In recent years, the implementation of the Six Sigma strategy got a substantial hike in every business sector like manufacturing, service, and process across the world. But Indian industrial practitioners are still oblivious about the efficacy of Six Sigma as compared to the worldwide exploration of this approach. So this is the prime time to make aware of them about Six Sigma approach and its implementation. The focus of the present paper is the illustration of the basic concept, industrial methodology, tools, and effective employment of Six Sigma in India so that any industrial practitioner may easily understand Six Sigma concept, methodology, and toolset available for continuous improvement. Moreover, the future research direction is described in the field of Six Sigma.

Research paper thumbnail of Maintenance Priorities for a Repairable System of a Thermal Power Plant Subject to Availability Constraint

International journal of performability engineering, Nov 1, 2016

Research paper thumbnail of A case study

The TQM Journal, Jan 6, 2012

PurposeSix Sigma within small and medium‐sized enterprises (SMEs) is rapidly emerging as the new ... more PurposeSix Sigma within small and medium‐sized enterprises (SMEs) is rapidly emerging as the new wave of change in Six Sigma. The purpose of this paper is to review the implications of applying Six Sigma methodology over the SMEs, taking a specific case of a bicycle chain manufacturing unit. The study could be a paradigm initiative towards high quality products and services at low cost for every SME.Design/methodology/approachBased on the literature, this paper proposes a process flow chart to present a one‐shot picture of the Six Sigma application in a bicycle chain manufacturing unit which falls in an SME environment. The methodology adopted is DMAIC methodology of Six Sigma, which had been mostly successful so far in large‐scale industries. The methodology has been applied to reduce the bush rejection rate (bush is an important component of a cycle chain) by reducing defects inherent in the processes. The statistical techniques such as two sample t‐test and process capability analysis have been used to establish the process capability before and after the Six Sigma application.FindingsThis paper is an attempt to justify the highly useful role of quality management techniques like Six Sigma for SMEs which are normally presumed to be in the domain of large industries. In this paper, Six Sigma methodology has been applied to a small unit manufacturing bicycles chains with dwindling productivity levels. After applying Six Sigma it was found that the chain manufacturing firm can increase its profit by controlling high rejection rate of cycle chain bush. Application of Six Sigma project recommendation brought up the process sigma level to 5.46 from 1.40 by reduction in bush diameter variation in the process of bicycle chain bush manufacturing. This increase in sigma level is equivalent to monetary saving of Rs 0.288 million per annum, which is a noteworthy figure for an industry of such level. The success of this study paves the way to further extend the Six Sigma application to more such industries working in the SME environment.Originality/valueThis paper provides documented evidence of Six Sigma implementation in a bicycle chain manufacturing unit which has been taken as representative of a small and medium‐size industry. The study will yield a great value to academics, consultants, researchers and practitioners of Six Sigma.

Research paper thumbnail of Integrating Agile Thinking into Maintenance Strategy Performance Analysis

International Journal of Process Management and Benchmarking, 2018

Research paper thumbnail of Studies on induction hardening of powder-metallurgy-processed Fe–Cr/Mo alloys

International Journal of Minerals, Metallurgy, and Materials, 2017

Research paper thumbnail of Production of AA6082-Si3N4 /Gr Hybrid Composite by a Novel Process and Evaluation of its Physical Properties

i-manager's Journal on Material Science, 2015

Research paper thumbnail of AA6061/B4C/Graphite/CeO2 Reinforced Hybrid Composite Development and Evaluation of Its Properties

Social Science Research Network, 2017

Research paper thumbnail of Risk Analysis of Water Treatment Plant Using Fuzzy-Integrated Approach

Harmony Search and Nature Inspired Optimization Algorithms, 2018

The study addresses and expounds the identification and prioritization of various causes of failu... more The study addresses and expounds the identification and prioritization of various causes of failure in the water treatment plant of an organization. The water treatment plant was being studied under the guidance of plants management team and data was collected. For identification of various causes of failure, fishbone diagram or cause and effect method has been used. A total of 16 causes of failure have been identified as a potential risk. The failure mode and effect analysis FMEA and Fuzzy methodology has been used for the proposed study. For FMEA, risk priority number (RPN) is used to prioritize failure causes. The uncertainty due to imprecise and vague expert judgment has been removed using fuzzy methodology. If-then rules are made in fuzzy inference system (FIS), and fuzzy RPN (FRPN) is obtained as output. The outputs of both methods are compared to get correct analysis. The average FRPN is evaluated as 5.375, that indicated that 4 out of 16 failure causes are critical for the system and require immediate and stringent attention from the maintenance department. The iron membrane filter, media filter choke acid dosing, sand/multimedia filter are identified as prominent causes of failure. Finally, the present methodology, under multiple sources of different and uncertain evaluation information is used to assist maintenance personnel for proper maintenance planning, reducing risks, improving the efficiency of the system and reducing the cost of the installation in water treatment plant.

Research paper thumbnail of Cost of poor quality reduction in auto sector: an exploration with Six-Sigma

International Journal of Six Sigma and Competitive Advantage, 2021

Research paper thumbnail of Total Fuzzy Agility Evaluation Using Fuzzy Methodology: A Case Study

Harmony Search and Nature Inspired Optimization Algorithms, 2018

The present study evaluates the agility of a medium-scale industry in the northern state of India... more The present study evaluates the agility of a medium-scale industry in the northern state of India. For evaluating agility, a ‘Total Fuzzy Agility Index’ is defined, which serves as a benchmark for assessing two parameters, namely agility level and Total Fuzzy Performance-Importance Index (TFPII). TFPII forms a basis for identifying principle obstacles in the process of increasing agility level. Once identified, principle obstacles are ranked for exploring gaps. In the present study, 132 agile enablers have been identified and used for evaluation out of which 13 have been assessed as obstacles. This study will serve as a decision support system for managements to identify obstacles, rank, and correct them for increasing agility level of the organization. This research paper analyses these issues and concludes by suggesting a future roadmap for successful implementation of agile practices.

Research paper thumbnail of Prioritizing Autonomous Maintenance System Attributes using Fuzzy EDAS Approach

Procedia Computer Science, 2020

Research paper thumbnail of A study on implementation of lean manufacturing in Indian foundry industry by analysing lean waste issues

Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2016

Lean proliferates the value-adding work by eliminating wastes and reducing incidental and non-val... more Lean proliferates the value-adding work by eliminating wastes and reducing incidental and non-value-adding work to a certain possible extent. Waste can be defined as anything other than the essential resources of people, machines, and materials that are needed to add value to the product. According to the lean concept, any action which does not directly enhance product’s value can be considered as waste. Analysis of lean waste issues is one of the primary steps to implement lean principles in many industries and the same is applicable for the foundry industry as well. The purpose of this article is to investigate the importance of various lean waste issues in Indian foundry industry for improvement in productivity and elimination of wastes, thereby initiating lean implementation. For the purposes of this study, we employed the survey questionnaire method to collect data against 17 lean waste issues from 71 middle- to senior-level professionals belonging to Indian foundry industry. T...

Research paper thumbnail of An empirical study on applicability of lean and green practices in the foundry industry

Journal of Manufacturing Technology Management, 2016

Purpose – The purpose of this paper is to investigate the applicability of lean and green practic... more Purpose – The purpose of this paper is to investigate the applicability of lean and green practices to foundry industry in India for improving productivity and eliminating waste, incorporating the sustainability into business performance measures. Design/methodology/approach – The study used survey questionnaire method to collect data against 16 lean and green practices from 71 middle- to senior-level professionals belonging to Indian foundry industry. The survey instrument of lean and green practices was developed based on a number of sources from the literature and formal discussions with academicians and foundry industry professionals. The responses were received on a five-point Likert scale ranging from least applicable to most applicable. Exploratory factor and reliability analyses are conducted to obtain and validate constructs and measure each constructs Cronbach’s α (i.e. a consistency coefficient). The lean and green practices are categorized into the four constructs, namel...

Research paper thumbnail of Parametric Study of Dry Sliding Wear Behavior of Hybrid Metal Matrix Composite Produced by a Novel Process

Metallurgical and Materials Transactions A, 2015

Research paper thumbnail of A study on microstructure of aluminium matrix composites

Journal of Asian Ceramic Societies, 2015

Research paper thumbnail of Effect of graphite reinforcement on physical and mechanical properties of aluminum metal matrix composites

Particulate Science and Technology, 2015

ABSTRACT This work focuses on the effect of graphite particles addition on the properties of AA 6... more ABSTRACT This work focuses on the effect of graphite particles addition on the properties of AA 6082 metal matrix composites fabricated by conventional stir casting method. The percentage of reinforcement was varied from 0% to 12% in a step of 3%. The results revealed that with the addition of graphite particles the micro and macro-hardness decreased by 11.11% and 10.44% respectively. The ultimate tensile strength also decreased by 5.88% with a reduction in percentage elongation from 8.7 to 6.8. The density decreased by 4.1% with an increase in porosity from 0.37% to 2.27% as the weight percentage of graphite particles increased from 0% to 12%.

Research paper thumbnail of Computational Support to Design and Fabrication of Traditional Indian Jewelry

Research paper thumbnail of Metallurgical and mechanical characterization of electron beam welded DP600 steel joints

Journal of Materials Science, 2011

Research paper thumbnail of Enigma and Growth of Business Incubators In India

International Journal of …, 2008

Page 1. www.IndianJournals.com Members Copy, Not for Commercial Sale Downloaded From IP - 66.249.... more Page 1. www.IndianJournals.com Members Copy, Not for Commercial Sale Downloaded From IP - 66.249.67.66 on dated 10-Jul-2010 International Journal of Applied Engineering Research ISSN 0973-2683 Volume 3 Number 10 (2008) pp. ...

Research paper thumbnail of Tribological and mechanical behavior of particulate aluminum matrix composites

Journal of Reinforced Plastics and Composites, 2014

Aluminum and its alloy are light in weight, ductile, strong and long lasting, having high corrosi... more Aluminum and its alloy are light in weight, ductile, strong and long lasting, having high corrosion resistance, good conductor of heat and electricity and are 100% recyclable. Despite all these good qualities, it has low wear resistance. But some applications entail high hardness and tensile strength, high modulus of elasticity than the conventional aluminum alloy with good tribological properties. Keeping in view the enhancement of mechanical as well as tribological properties with reduction in weight, the aluminum alloy is reinforced with a second phase which is hard and brittle, and the newly formed material has better mechanical and tribological properties. The paper reviews the various manufacturing processes of aluminum matrix composites, and it was found that the mechanical and tribological properties of the single reinforcement composites are better as compared to pure aluminum and its alloys irrespective of the aluminum matrix composites manufacturing process. Further, it w...