Improving Productivity and Sustainability by Using Six Sigma Methodology: A Case Study on Indian Cement Manufacturing Industry

Abstract

This article presents a detailed and thorough analysis of the Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) methodology’s application in a cement plant located in Odisha, India, concentrating on the enhancement of productivity. The initial operational context is carefully unveiled, portraying a daily productivity of 3178 tons. The systematic and strategic implementation of the Six Sigma DMAIC approach leads to a remarkable 7.7% increase, culminating in an elevated daily productivity of 3425 tons. Moving beyond the productivity paradigm, the study delves into the intricate dimensions of environmental sustainability, scrutinizing specific water consumption, specific energy consumption, specific emissions, and specific wastage. The outcomes portray positive advancements in these sustainability metrics, signifying a successful amalgamation of heightened productivity and a heightened sense of environmental responsibility. Moreover, the study underscores a substantial annual cost benefit of 10 crores, affirming the economic viability inherent in the Six Sigma initiative. The distinctiveness of this research lies in its meticulous scrutiny of productivity enhancements within the Six Sigma DMAIC framework, spotlighting its direct and advantageous influence on the industry’s sustainability performance. This comprehensive investigation is poised to provide valuable insights to organizations seeking a harmonious equilibrium between operational efficiency and environmental stewardship, encapsulating the essence of Six Sigma, DMAIC, Productivity, and environmental sustainability.