Successful Projects from the Application of Six Sigma Methodology (original) (raw)
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International Journal of Engineering Research and Technology (IJERT), 2016
https://www.ijert.org/implementation-of-six-sigma-and-other-cost-reduction-techniques-for-improving-quality-in-selected-manufacturing-industries https://www.ijert.org/implementation-of-six-sigma-and-other-cost-reduction-techniques-for-improving-quality-in-selected-manufacturing-industries In the manufacturing industries the major concern is to optimize the quality of product and production cost. This problem can be reduced by using various techniques. The Six Sigma technique is mostly used to enhance the quality of product, reduce cost and process improvement for the manufacturing industries. This paper identifies the different quality and cost reduction techniques used in selected industries and also find out various processes which reduces source of variation and improves quality and productivity, results increase in customer satisfaction.
Modern Concepts Of The Six Sigma Methodology For Improving The Quality
Annals - Economy Series, 2018
Product quality is generally accepted as being crucial in today’s industrial business. The traditional aspects of product quality are connected to product design (translating customer demands into attractive features and technical specifications) and to the design and specification of high performance production processes with low defect rates. Quality management is the general expression for all actions leading to quality. Quality management is focused on improving customer satisfaction through continuous improvement of processes including the removal of uncertain activities, and continuous improvement of the quality of processes, products and services. The quality management includes four key processes, such as quality planning, quality assurance, quality control and quality costs. The main accent in this paper will be on quality control and the application of one of the quality control tools in order to improve it. Six Sigma is different from other quality improvement concepts in...
Implementation of Six Sigma in a Manufacturing Process: A Case Study
This paper presents a Six Sigma project conducted at a semiconductor company dedicated to the manufacture of circuit cartridges for inkjet printers. They are tested electrically in the final stage of the process measuring electrical characteristics to accept or reject them. Electrical failures accounted for about 50% of all defects. Therefore, it is crucial to establish the main problems, causes and actions to reduce the level of defects. With the implementation of Six Sigma, it was possible to determine the key factors, identify the optimum levels or tolerances and improvement opportunities. The major factors that were found through a design of experiments 3 factors and 2 levels were: abrasive pressure (90-95 psi), height of the tool (0.06-0.05) and cycle time (7000-8000 msec.). The improvement was a reduction in the electrical failures of around 50%. The results showed that with proper application of this methodology, and support for the team and staff of the organization, a positive impact on the quality and other features critical to customer satisfaction can be achieved Significance: Six Sigma literature is extensive, although there are many reports on its application, it is extremely important the gathering empirical evidence to build a body of Six Sigma with better explanatory capability.
Case study in Six Sigma methodology: manufacturing quality improvement and guidance for managers
This article discusses the successful implementation of Six Sigma methodology in a high precision and critical process in the manufacture of automotive products. The Six Sigma define–measure–analyse–improve–control approach resulted in a reduction of tolerance-related problems and improved the first pass yield from 85% to 99.4%. Data were collected on all possible causes and regression analysis, hypothesis testing, Taguchi methods, classification and regression tree, etc. were used to analyse the data and draw conclusions. Implementation of Six Sigma methodology had a significant financial impact on the profitability of the company. An approximate saving of US$70,000 per annum was reported, which is in addition to the customer-facing benefits of improved quality on returns and sales. The project also had the benefit of allowing the company to learn useful messages that will guide future Six Sigma activities.
Implementation of Six Sigma Method for Quality Improvement
construction sector is a topmost sector in India.. Construction management and technology are the two key factors which affects the development of the construction sector. The main of the project is to study the quality of building work. Study the various factors that affect the quality and customers need are main aim of this work. For that quality terms are studied. DMAIC methodology is helpful to this work. The result of six sigma is based on the quality factors. The purpose of this study is to identify the factors of G+4 building. The comparative studies are done and it shows the exact quality of work. This study will help us for future work.
Application of Six-Sigma for Process Improvement in Manufacturing Industries: A Case Study
This is an era of quality management and quality is a parameter for the selection of a product or service because the customer wants a defects free product or service. Six Sigma is a quality improvement approach that aims to reduce the number of defects up to 3.4 parts per million. In the last three decades, it helped several companies to enhance the capability of their processes and to increase the level of quality of their product or service. This case study based research deals with application of DMAIC (Define, Measure, Analyze, Improve and Control) methodology of Six Sigma to reduce the machine downtime for process improvement. The tools and techniques used during the analysis are Process Mapping (SIPOC Diagram), Process Flow Chart, Process Capability Analysis, Histogram, Pareto Chart, Pie Chart, Cause and Effect Diagram, Brainstorming, Affinity Diagram and ANOVA. The results of this study show that sigma value has improved from 2.79 Sigma to 2.85 Sigma. This study also highlighted the five critical problems (reasons) of Downtime, which are i.e. Electricity Problem, Shortage of Material, Quality Issues, Machine Fault and Reactive Maintenance. The valuable principles and practices of Six Sigma will do well by continuously refining the organizational culture. Time and commitment both are required and compulsory to bring change in cultural before they are strongly implanted into the organization. I do assure that this research study will provide opportunities to the organizations for the better implementation of six sigma projects.
Six Sigma process improvements in automotive parts production
ABSTRACT Purpose: of this paper: In the paper is presented a Six Sigma project, undertaken within company for production automotive parts, which deals with identification and reduction of production cost in the deburring process for gravity die-castings and improvement of quality level of produced parts. Design/methodology/approach: The objectives are achieved by application of Six Sigma approach to quality improvement project in automotive industry. The applied Six Sigma approach includes team works through several phases: Define, Measure, Analyze, Improve, and Control (DMAIC). Findings: Systematic application of Six Sigma DMAIC tools and methodology within an automotive parts production results with several achievements such are reduction of tools expenses, cost of poor quality and labours expenses. It was shown that Six sigma is an effective way to find out where are the greatest process needs and which are the softest points of the process. Also, Six sigma provide measurable indicators and adequate data for analytical analysis. Research implications: The possibility of application of several Six Sigma tools such are thought process mapping, Pareto diagrams, process mapping, cause and effect matrix, and analysis of variation and capability studies. Practical implications: Improvements through reduced Production time, Control time, Material and Internal scrap have been yield significant financial. Furthermore, this pilot project enabled introduction of Six Sigma methodology in wider range of manufacturer activities. Originality/value: The paper researches the possibility of Six Sigma application within manufacturing process. This paper is of the value to researcher in the field of quality management and quality improvement, as well as to professionals in the manufacturing industry, wherever the quality improvement is an issue.
Implementation of Six Sigma to Reduce Cost of Quality: A Case Study of Automobile Sector
In the era of cut-throat competition, especially in automobile sector, success of an organization resides in its ability to respond quickly to the needs of its customers. These customer needs must be attended with minimum manufacturing costs, minimum lead time to launch the product in market, and delivering better performance than the existing competitors in the market. Six Sigma is a powerful methodology which ultimately helps in cost reduction. Because of defect prevention and improved product and processes, it leads to increase in profitability and market share. This is accomplished through the use of two Six Sigma sub-methodologies: DMAIC and DMADV (Andersson et al., TQM Mag 18:282-296, 2006). By adopting Design For Six Sigma methodology in the design stage itself leads to launch of a product with maximum quality performance, with tighter tolerances, and with reduced or no defects. This paper considers cost of poor quality as the loss imparted to society from the time the product is shipped, and deals with the applications and benefits of Six Sigma methodology and its positive impact on cost of poor quality. A case study is presented, which enabled application of six sigma methodology in wider range of manufacturing activities. This paper is of value to the researcher in the field of quality management, as well as professionals in the manufacturing industry, wherever the quality improvement is an issue. Quality costs or Cost of Quality is a means to quantify the total cost of quality-related efforts and deficiencies (Banuelas and Antony,
Application of Six Sigma in a company Automotive in Morocco
E3S Web of Conferences
Customer satisfaction is the key to success in all organizations and this satisfaction has a correlational relationship with the quality so that is why we notice that during the last ten years, the automotive sector focuses on the quality whose new strategy reinforces to develop quality and anchors Morocco in the global automotive industry. This article describes the use of Six Sigma through the DMAIC method (Define, Measure, Analyze, Improve and Control) during production lines in a wiring company. The objective is to reduce the defect rate to improve the quality of the product. After defining the workplace and measuring the defect rate, a structured analysis was done to find the root causes and then actions were implemented to reduce the defect rate. To this effect, the deployment of this method has reduces the rate of defects. The use of the Six Sigma method plays a key role in improving the quality of the product as well as financial gains for the different companies.
The Main Benefits of Application of Six Sigma for Productive Excellence
Quality Innovation Prosperity, 2022
Purpose: The present paper addressed the application of the Six Sigma method for process management to reduce the variability and scrap of packages manufactured at a company located in the city of Rio de Janeiro. Methodology/Approach: Exploratory research was conducted to understand the context, analyse, and create familiarity with the problems identified in the company, making them more explicit. Findings: Through Define, Measure, Analyze, Improve, Control (DMAIC) the company was able to identify the main causes of customer complaints and the factors that led to these complaints. Using management tools, it was possible to solve the problems with packaging outside the specifications, which was the reason for complaints from customers. The benefits of this research were the identification and analysis of the quality management tools. Research Limitation/Implication: The present research had as a limitation the application of the method is only one company, so it is proposed as a future study of the application in different production processes of different organizations. Originality/Value of paper: It was evidenced that there is a positive relationship between the application of Quality management methods and company billing, as there was an increase of 1.7% in company billing. In past surveys, new possibilities for improvement to be addressed emerged, making the team aware of the need to continue the process of continuous improvement.