Using Six Sigma DMAIC to Improve the Quality of the Production Process: A Case Study
TL;DR: This paper presents how to implement the DMAIC cycle as an element of continuous improvement in practice and the propositions of improvements, which can be implemented in the organization in order to increase the effectiveness of production process.
About: This article is published in Procedia - Social and Behavioral Sciences.The article was published on 2018-01-01 and is currently open access. It has received 78 citations till now. The article focuses on the topics: DMAIC & Six Sigma.
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TL;DR: In this paper, a study carried out in a food processing industry in south India, with major focus on the production and packaging processes, the main objective of the study was to identify and eliminate the bottlenecks in these processes, and to improve the production by applying various techniques such as DMAIC (Define, measure, analyze, improve and control), SIPOC, VSM, ANOVA and 5S methods.
21 citations
TL;DR: In this article , a systematic approach to analysis to find the root cause of defects in the product assembly process, a method of diagnosing defective products as well as the application of charts to the analysis of waste products, and improving quality by applying basic quality management tools such as Pareto charts, fishbone diagrams, value stream mapping, man-machine chart, and failure tree analysis (FTA).
Abstract: Intelligent integrated production systems are always of interest to production planners. However, in order to deploy and improve from a mere processing factory to a processing factory with an integrated intelligent production system, it requires a team of employees, engineers, and managers to always have a spirit of innovation, continuously improving existing semi-automatic equipment into automatic ones, aiming to move towards a smart factory. The result of this research is to reduce waste in the process of assembling mechanical products by applying the DMAIC process (Define, Measure, Analysis, Improve, Control), lean six sigma tools, the test of variance, hypothesis testing and experimental design, IBM SPSS 2020, Matlab2019a and Minitab 18 software are used for data analysis and Solid work software is used to design and simulate mechanical parts. This study shows a systematic approach to analysis to find the root cause of defects in the product assembly process, a method of diag-nosing defective products as well as the application of charts to the analysis of waste products, and improving quality by applying basic quality management tools such as Pareto charts, fishbone diagrams, value stream mapping, man-machine chart, and failure tree analysis (FTA). Clearly identify the types of waste such as components sliding on top of each other without rust, and surface roughness of metal products that do not meet the standards. Experimental design models and statistical
18 citations
TL;DR: In this paper, a structural equations model is presented to identify the relationships between managerial commitment, Six Sigma implementation strategy, investments in human resources and the economic benefits obtained; and five hypotheses are proposed.
Abstract: Six Sigma is a methodology widely used in manufacturing production to guarantee quality and several factors facilitate its success. This paper presents a structural equations model to identify the relationships between managerial commitment, Six Sigma implementation strategy, investments in human resources and the economic benefits obtained; and five hypotheses are proposed. These variables are also related to sustainability, especially human resources, a paradigm very combinable with Six Sigma. The model is evaluated using partial least squares and information obtained from 301 Mexican manufacturing companies from different industrial sectors. The results indicate that managerial commitment is the basis for Six Sigma success, but requires an adequate implementation strategy focused on customers and their needs, which must integrate an investment plan in human resources that is focused on training and teamwork. In addition, managers must have a reward program that encourages motivation and recognizes the achievements of the human resources involved.
17 citations
TL;DR: In this article, the authors illustrate the application of Lean Six Sigma in the service sector of one big energy company and demonstrate that following specific Lean Sig Sigma steps, the company exceeded the established target, significantly improving actualization rate from 2.6% to 20% in just 3 months.
12 citations
28 Feb 2021
TL;DR: In this article, the root cause of major defects in aluminum castings using the defect diagnostic approach as well as cause and effect diagram was identified. And the proposed quality improvements using the FMEA tool.
Abstract: The global market demand for automotive wheels with alloy materials is 55%, which is quite high compared to other materials such as steel, magnesium, chromed, and carbon fiber. The high competition of the global alloy wheels market demands to be able to offer quality alloy wheels. The purpose of this research is to reduce the number of defects in the casting process step by using the Define Measure Analyze Improve Control (DMAIC) method. This study shows the systematic approach to find the root cause of major defects in aluminum castings using the defect diagnostic approach as well as cause and effect diagram. Quality improvement using quality tools, namely the Pareto diagram, fishbone diagram. The major defects for the rejections during production were identified as leak defects, porosity motive holes, and oval defects. In determining the proposed quality improvements using the FMEA tool. The results of data processing on the calculation of process capabilities and product performance show improvements after quality improvements in the casting process. Product performance from DPMO = 15.462, sigma level = 3.6 to DPMO = 8.186 and sigma level = 3.9. The effect of decreasing the percentage of defects could save production costs by IDR 413.350.000. Therefore, the application of the DMAIC method can provide a significant improvement in product quality and impact on production cost savings.
8 citations
Cites background from "Using Six Sigma DMAIC to Improve th..."
...DMAIC is a closed-loop process that eliminates unproductive steps, often focuses on new measurements, and applies technology for continuous improvement [25]....
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