Six Sigma DMAIC phases application in Y company: a case study

Abstract

Six Sigma has been used by large organisations to improve the performance of their manufacturing processes. The objective of this paper is to analyse the problem of increasing demand of flour in wafer biscuit production in Y Company. This problem leads to decrease profit and external customer satisfaction. In this study, define, measure, analyse, improve and control (DMAIC) methodology of Six Sigma is used to develop the solutions for the problem. Root causes are determined by using cause-and-effect analysis. Pareto chart helped to focus attention on the major important root causes. Moreover, a brainstorming concept was conducted with experts from the production, maintenance and quality control departments, which helped in formulating the solutions. The study presents the applicability, feasibility and impact of DMAIC methodology on the company, which carried out the reduction in deviation rate of flour material usage from approximately 27.55-10.45% on the production line.