Define, Measure, Analyze, Improve, Control Research Articles

Enhancing the process capability of machining process of boring tool holder by application of six sigma methodology

This paper aims to identify the causes for the rejections of Boring Tool Holders (BTH) and develop a process control plan. From the CTQ characteristics, high rejection rates were due to the variations in key size and bore size dimensions. Define-Measure-Analyse-Improve-Control (DMAIC) approach was adopted to solve the problem. Data was collected and X-bar R control charts were drawn. The process was found not to be in statistical control. Fishbone diagram was constructed, and the root causes were narrowed down to tool wear and improper clamping of angular vise. Corrective actions were taken to make sure the angular vise was clamped properly and the tool life was monitored. This led to the process being in statistical control and thus, process capability analysis was conducted. All the values were found to be within the specification limits. The obtained Cpk values were 1.09 and 1.15 for key size and bore size respectively. This was later institutionalized by developing a process control plan that constituted the control stage.

A Health Technology Assessment in Maxillofacial Cancer Surgery by Using the Six Sigma Methodology.

Squamous cell carcinoma represents the most common cancer affecting the oral cavity. At the University of Naples “Federico II”, two different antibiotic protocols were used in patients undergoing oral mucosa cancer surgery from 2006 to 2018. From 2011, there was a shift; the combination of Cefazolin plus Clindamycin as a postoperative prophylactic protocol was chosen. In this paper, a health technology assessment (HTA) is performed by using the Six Sigma and DMAIC (Define, Measure, Analyse, Improve, Control) cycle in order to compare the performance of the antibiotic protocols according to the length of hospital stay (LOS). The data (13 variables) of two groups were collected and analysed; overall, 136 patients were involved. The American Society of Anaesthesiologist score, use of lymphadenectomy or tracheotomy and the presence of infections influenced LOS significantly (p-value < 0.05) in both groups. Then, the groups were compared: the overall difference between LOS of the groups was not statistically significant, but some insights were provided by comparing the LOS of the groups according to each variable. In conclusion, in light of the insights provided by this study regarding the comparison of two antibiotic protocols, the utilization of DMAIC cycle and Six Sigma tools to perform HTA studies could be considered in future research.

Risk and DoE-Based DMAIC Principle to the Multipurpose-RP-HPLC Method for Synchronous Estimation of Anti-Hypertensive Drugs Using AQbD Approach.

Hypertension is a major health problem found in people throughout the world and numerous fixed-dose combination (FDC) products of telmisartan are available in the local market for its treatment. Several chromatography methods such as reversed-phase (RP)-HPLC and HPTLC methods have been published for estimation of FDC products of telmisartan with hydrochlorothiazide, atorvastatin, and amlodipine. No RP-HPLC method has been reported yet for synchronous estimation of FDC products of telmisartan, which would save analysis time, cost, and solvent. A multipurpose RP-HPLC method has been developed for synchronous estimation of FDC products of telmisartan using the analytical quality by design approach based on risk- and design of experiment (DoE)-based define, measure, analyse, improve, control (DMAIC) principles. The risk-based DMAIC principle was implemented by risk parameter identification and assessment as per the ICH Q9 guideline. The DoE-based DMAIC principle was applied by response surface analysis using a Box-Behnken design. The method operable design ranges were navigated and a control strategy was set for the development of the method as per the analytical target profile (ATP). Chromatographic separation was performed using Shimpack ODS C18 column and acetonitrile: 0.1% (v/v) triethylamine (pH 6.5), keeping a flow rate of 1.0 mL/min. The method was validated as per the ICH Q2 (R1) guideline. The developed method was applied for synchronous estimation of seven different anti-hypertensive products. The developed method is an eco-friendly and economical alternative to published chromatography methods for the analysis of anti-hypertensive products. Hence, the developed method can be used as a multipurpose RPLC method for quality control of anti-hypertensive products in the pharmaceutical industry. A multipurpose RPLC method for synchronous estimation of antihypertensive products of telmisartan was developed, saving analysis time, cost, and solvent. The developed method was applied to the synchronous estimation of seven different anti-hypertensive products.

Improving logistics supplier selection process using lean six sigma – an action research case study

Purpose Outsourcing logistical activities have become a widely used approach for firms to avoid high fixed costs and heavy investment requirements and to achieve competitive advantages. Lean six sigma (LSS) has been accepted globally across sectors as a management strategy for achieving process excellence. The purpose of this paper is to feature the application of LSS for improving the supplier selection process (SSP) of outsourced logistics services in a multinational health-care company. Design/methodology/approach This study is based on an action research case study conducted on the SSP of the freight and distribution department in a multinational health-care company. This paper reports on the application of the LSS define-measure-analyze-improve-control (DMAIC) approach for reducing supplier selection lead time. Findings The study features a real-world case study of the LSS DMAIC application to improve the supplier selection process of a large health-care company. The key issues that were identified are lack of information visibility, top-down changes and unclear communication lines. To counteract these three root causes, the lean six sigma techniques that are implemented are the 5S, stakeholder analysis and standard operating procedure. Research limitations/implications This research provided empirical evidence of how practical challenges in SSP can be managed with the use of LSS. It further proposed plausible solutions for reducing and sustaining improved outcomes. As the study is limited to one case, the validity of the results can be improved by including more organisations and more case studies from other similar organisations. Originality/value Research in supplier selection processes rarely links continuous improvement ideology such as LSS to support strategic selection and procurement of logistics services. This paper could serve as a resource for both practitioners to derive useful implications and to academicians as it contributes to the LSS body of knowledge for further theory testing.

Enhanced Recovery: A Decade of Experience and Future Prospects at the Mayo Clinic.

This work aims to describe the implementation and subsequent learnings from the first decade after the full implementation of enhanced recovery pathway for colorectal surgery at a single institution. This paper will describe the diffusion efforts and plans through the Define, Measure, Analyze, Improve, Control (DMAIC) process of ongoing quality improvement and through research efforts. The information applies to all readers that provide surgical care within their organization as the fundamental principles of enhanced recovery for surgery are applicable regardless of the setting.

Application of fuzzy TOPSIS in the Analyze phase of the DMAIC cycle to aid decision-making

This paper reports the use of multicriteria analysis in the Analyze phase of the DMAIC (Define-Measure-Analyze-Improve-Control) cycle for continuous improvement. The research was carried out in a tissue paper factory located in southern Brazil. A sample of 64 parts of 16 different reels of recycled paper was used. A problem regarding paper quality variability was detected, presenting a scrap index ranging between 9% and 23%, compromising machine productivity and product sales. This motivated the implementation of a structured project supported by the application of the DMAIC cycle. The project team (machine operators, maintenance staff, supervisor, and data analyst) defined the evaluation criteria and determined the control intervals and their equivalence with linguistic variables to support the necessary evaluations for the application of fuzzy TOPSIS (Technique for Order of Preference by Similarity to Ideal Solution). The criteria were C1-Longitudinal Strength (Kgf), C2-Longitudinal Elongation (mm), C3-Cross-strength (kgf), C4-Cross-elongation (mm), C5-Weight (g/m²), and C6-Humidity (%). The results showed that samples with the same ranking had the lowest scrap indexes in the subsequent process. Also, the criterion C5 had a more significant impact on the quality of the product than the other criteria, which was determined from the DMAIC sequence. Improvements related to C5 should be prioritized. The fuzzy TOPSIS method presented is a flexible tool, adapting itself to the solution of the problem and contributing to the decision-making process.

Minimizing soft tube defect level using six sigma method at PT Era Variasi Intertika

The purpose of this research is to examine the level of sigma that has been achieved in the production of soft tube product, determine factors caused the defect of soft tube production, provide suggestions for improvements to reduce defective products, and estimate the sigma level that will be achieved by PT Era Variasi Intertika in implementing the suggestions. The research method used was mix of qualitative and quantitative methods. The data analysis method used is Six Sigma Method using DMAIC (Define – Measure – Analyze – Improve – Control) steps. From data analysis, the sigma level achieved by the company is 3.52. The main factors causing defects of soft tube production in PT Era Variasi Intertika are problem of blanket printing, unclean production area, temperature of sealing machine which is not high enough, broken molding part in printing machine, careless employee, and machine error. The estimated sigma level that will be achieved by company when applying suggestions of improvement is 4.37. The defect will be reduced by 23.41%. Furthermore, doing these suggestions will decrease the risk of defect products that consumers will receive so the customer satisfaction will also increase.

Health technology assessment through Six Sigma Methodology to assess cemented and uncemented protheses in total hip arthroplasty.

The purpose of this study is to use Health Technology Assessment (HTA) through the Six Sigma (SS) and DMAIC (Define, Measure, Analyse, Improve, Control) problem-solving strategies for comparing cemented and uncemented prostheses in terms of the costs incurred for Total hip arthroplasty (THA) and the length of hospital stay (LOS). Multinomial logistic regression analysis for modelling the data was also performed. Quantitative parameters extracted from gait analysis, electromyography and computed tomography images were used to compare the approaches, but the analysis did not show statistical significance. The variables regarding costs were studied with the Mann-Whitney and Kruskal-Wallis tests. No statistically significant difference between cemented and uncemented prosthesis for the total cost of LOS was found, but the cost of the surgeon had an influence on the overall expenses, affecting the cemented prosthetic approach. The material costs of surgery for the uncemented prosthesis and the cost of theatre of surgery for the cemented prosthesis were the most influential. Multinomial logistic regression identified the Vastus Lateralis variable as statistically significant. The overall accuracy of the model is 93.0%. The use of SS and DMAIC cycle as tools of HTA proved that the cemented and uncemented approaches for THA have similar costs and LOSy.

Quality control of cutter case at PT. X with six sigma approach

Quality control is a system of maintaining the quality of products on an ongoing basis. In the industrial world, quality control is essential to meet customer demand. The problem formulated in this study is the assessment of the Defect of the Cutter Case produced by PT. The object in this study is the Cutter Case product. The number of samples used was 450 units. The Cutter Case will be inspected for the number of defective products and defect criteria that are met for each product unit, and the length and width of the product surface. Rules for the type of defect studied were melting, non-jagging, and bent. The method used in solving problems in this study is the Six Sigma method, namely DMAIC (Define, Measure, Analyse, Improve, Control).

Energy Efficiency Analysis in a Textile Company Using DMAIC Approach

Textile industries generally consume a significant amount of electricity in their business operations, hence, efforts to reduce their consumption is necessary. This study assesses the energy consumption and energy saving opportunities in a textile company in Indonesia. A structured energy audit using Define-Measure-Analyze-Improve-Control (DMAIC) was implemented in the Spinning department. The evaluation indicates that 80% of the Specific Energy Consumption (SEC) are dominated by the factory air conditioner and chiller which is corresponding to 515 kWh/kg and 219 kWh/kg respectively. The Coefficient of Performance (COP) of the plant cooling system is 7.41 which conforms to the COP national standard. Further energy-saving opportunities include closing the door and other gateways of the air, replacing the refrigerant material from Freon R-134 to Musicool Mc-134, and installing inverter on mist nozzle motor, evaporator pump, condenser pump, and cooling tower.

Analysis of Aluminium Alloy Wheels Product Quality Improvement Through DMAIC Method in Casting Process: A Case Study of the Wheel Manufacturing Industry in Indonesia

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.

Analysis of Shrinkage Defect in Sand Casting by Using Six Sigma Method with Taguchi Technique

Casting industries play a major role in the field of manufacturing. The production of complex shape and size products is manufactured in a single process, which cannot be produced in other manufacturing processes. Because the other process needs more than one step to convert a raw material into a product. When producing the casting, the quality of the casting should be maintained without defects. This is not possible as we can’t produce a cent percentage of accuracy. But the percentage of defects can be reduced with the help of certain quality control tools and techniques. In this paper, the main focus is to reduce the shrinkage defect which occurs in the External Bearing Ring of ductile cast iron which is produced in the leading casting industry in Coimbatore. The data have been collected from the industry for the six months and the defects have been identified with the help of the Six-Sigma DMAIC (Define, Measure, Analyze, Improve, Control) technique. The quality control tools are applied in different stages of the DMAIC technique for identifying and controlling the defects. Also, the Taguchi technique is applied for creating the L9 orthogonal array from the Minitab software. Finally, the best possible solution is obtained and it is suggested to the industry for defects reduction.

Comprehensive Strategy to Inculcate Professional Skills among First-Year Students: A Collaborative Learning Approach

Inculcating teamwork, communication skills, and lifelong learning are essential metrics of Outcome Based Engineering (OBE). Ensuring these in early professional courses will enhance the ability of the students to adopt the OBE effectively in the forthcoming semesters. Effective planning and deployment of pedagogy of engagement will aid the students and faculty members to attain the desired outcomes with effective utilization of resources. This article unearths the challenges and documents the lessons learned in deploying collaborative learning in the First Year (FY) engineering education. It establishes a comprehensive assessment methodology from OBE perspective. Further, it addresses professional skills such as teamwork, communication skills, and lifelong learning in a structured manner. The Action Research methodology is adopted by taking into account the OBE approach enshrined in the Programme Outcomes (POs) as suggested by the Indian statutory bodies. The collaborative learning approach of 'Student, Teams, Achievement, Division' (STAD) is utilized by establishing a heterogeneous group. The Define-Measure-Analyze- Improve-Control (DMAIC) approach is used for project deployment and sustainment. Statistical analysis is used to interpret the results effectively. The study shows that the desired outcomes are achieved with a minimum duration of the teaching-learning process. Moreover, statistical analysis shows that even weaker students can reach the set attainment target due to heterogeneous group formation and collaborative learning. Eventually, the structured approach assists in developing a framework for the effective Shreeranga Bhat Department of Mechanical Engineering, St Joseph Engineering College, Mangaluru, Karnataka, India shreerangab@sjec.ac.in deployment of collaborative learning by establishing robust assessment tools to address the POs related to professional skills. The study shows that collaborative learning can be effectively deployed in FY engineering education with specific reference to POs related to professional skills within the optimal duration, provided a structured approach is embraced. It is also observed that heterogeneous group formation assists slow learners to elevate themselves to progressive learners due to teamwork and the influence of wiser students.

A Six Sigma DMAIC methodology as a support tool for Health Technology Assessment of two antibiotics.

Health Technology Assessment (HTA) and Six Sigma (SS) have largely proved their reliability in the healthcare context. The former focuses on the assessment of health technologies to be introduced in a healthcare system. The latter deals with the improvement of the quality of services, reducing errors and variability in the healthcare processes. Both the approaches demand a detailed analysis, evidence-based decisions, and efficient control plans. In this paper, the SS is applied as a support tool for HTA of two antibiotics with the final aim of assessing their clinical and organizational impact in terms of postoperative Length Of Stay (LOS) for patients undergoing tongue cancer surgery. More specifically, the SS has been implemented through its main tool, namely the DMAIC (Define, Measure, Analyse, Improve, Control) cycle. Moreover, within the DMAIC cycle, a modelling approach based on a multiple linear regression analysis technique is introduced, in the Control phase, to add complementary information and confirm the results obtained by the statistical analysis performed within the other phases of the SS DMAIC. The obtained results show that the proposed methodology is effective to determine the clinical and organizational impact of each of the examined antibiotics, when LOS is taken as a measure of performance, and guide the decision-making process. Furthermore, our study provides a systematic procedure which, properly combining different and well-assessed tools available in the literature, demonstrated to be a useful guidance for choosing the right treatment based on the available data in the specific circumstance.

Lean Manufacturing Integration in Reducing the Number of Defects in the Finish Grinding Disk Brake with DMAIC and FMEA Methods in the Automotive Sub Industry Company

This automotive company is a company engaged in the automotive components of motorcycles. Its main product is Disk Brake. Automotive companies produced an average defective product in Disk Brake production for the January 2019 – December 2019 period of 1.72%, while the tolerance limit of the company was 1%, where there was a difference of 0.72%. This study aims to reduce the number of defects by providing recommendations for improvement proposals. The method used is DMAIC (Define, Measure, Analyze, Improve, Control) by calculating the company’s sigma value and using FMEA (Failure Mode and Effect Analysis) tools to improve the problem. The Define stage creates SIPOC and CTQ (Critical to Quality) diagrams. At the Measure stage, the results of the calculation of the sigma value obtained a DPMO of 3446.41 with a sigma value of 4.20. The most dominant type of defect in disk brakes is thin material based on the analysis results using the Pareto diagram at the Analyze stage. The causes of disk brake defects are obtained using a fishbone diagram. At the Improve stage, the FMEA calculation found the most potential problem-causing factors, namely the availability of components with an RPN (Risk Priority Number) value of 448 and 5W + 1H analysis, an improvement proposal was obtained to schedule maintenance and replacement of components regularly.

Parametric optimization of hot forging process: a six sigma based approach

One of the major concerns for industries in the modern world is to focus efforts on producing high quality products with minimal costs. Various quality improvement philosophies have emerged in recent times, Six Sigma being one of the most practical and efficient techniques for quality improvement of processes. In this work, Six Sigma based DMAIC (Define, Measure, Analyze, Improve, Control) approach is used to enhance productivity and quality performance, and to make the hot forging process robust to quality variations. Finite element method has been employed for the simulation of hot forging of the connecting rod. The influence of design and process parameters is investigated for the response ‘forging die load’. Analysis of various critical parameters and the interaction among them has been carried out with the help of Taguchi’s method of experimental design. To further optimize the response and make the analysis more precise and robust, response surface methodology has been incorporated. Parameters have been optimized, leading to the accomplishment of a minimized forging die load which is verified using a confirmation experiment. Confirmatory results reveal the potential of the DMAIC approach of Six Sigma in optimizing the process parameters successfully and thereby present significant applicability in the industry.

Process capability improvement of an eight-head liquid filling machine by the reduction in volume variation

Filling is the process in which liquid and semi liquid products are filled in a container according to the specified requirement. It has a wide range of importance in various industries like dairy products, oil & lubricants, pharmaceuticals, food and beverages, pesticides, chemicals and cosmetic products. Liquids of low to medium viscosity can be filled using these type of filling machines. Filling machine reduces the operational cost and it is not complex to handle where it contributes in obtaining high rate of liquid production in industries. In this paper filling capability factor of machine in a liquid filling line is studied in terms of statistical process control. Filling capability is increased by the application of total production maintenance. Upon continuous usage, the liquid filling spare parts deteriorate which causes volume variation. Define-Measure-Analyze-Improve-Control (DMAIC) approach is applied to analyze and solve this problem. The root causes for volume variation were identified and effective solutions were implemented to decrease the volume variation and thereby enhance the capability of filling.

Waste reduction of polypropylene bag manufacturing process using Six Sigma DMAIC approach: A case study

In the current study, minimization of waste in terms of sack rejection at a polypropylene bag manufacturing process is achieved. The Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) app...

Analisis Pengendalian Kualitas Line Produksi Body Inner K56 dengan Tahapan DMAIC di PT. KMIL (Kurnia Mustika Indah Lestari)

One of the products of PT. Kurnia Mustika Indah Lestari is the inner body of K56. In one month the product rejects amounted to 2.0%, which exceeds the tolerance limit set by the company, namely 0.5%. It is necessary to carry out research aimed at determining the root of the dominant problem that causes rejection of the inner K56 body and determining the quality improvement proposal. The method used is quality control with the DMAIC stage. The results of the research findings show that the dominant root cause of reject burry is that work instructions are not carried out (Method) and working in a hurry to quickly rest (Human). The reject scratch type is due to lack of skill (Method) and pursuing a lot of rest time (Human). The recommendation to improve the quality of the reject burry is to carry out work instructions, be more careful when loading the material into the dies, always clean the inside of the dies, checkman supervises the manpower of the production process so that it works according to cycle time. For the reject scratch type, it is to provide training for man power, give warning instructions for the placement of parts while running the process, set rules for working times that are not too fast, take advantage of spare time to clean the machine.&#x0D; Keywords: Quality, Reject, DMAIC (Define, Measure, Analyze, Improve, Control).

Simulation-based lean six sigma for Industry 4.0: an action research in the process industry

PurposeThe primary aim of this article is to ascertain the modalities of leveraging Lean Six Sigma (LSS) for Industry 4.0 (I4.0) with special reference to the process industries. Moreover, it intends to determine the applicability of simulation-based LSS in the automation of the mineral water industry, with special emphasis on the robust design of the control system to improve productivity and performance.Design/methodology/approachThis study adopts the action research methodology, which is exploratory in nature along with the DMAIC (define-measure-analyze-improve-control) approach to systematically unearth the root causes and to develop robust solutions. The MATLAB simulation software and Minitab statistical software are effectively utilized to draw the inferences.FindingsThe root causes of critical to quality characteristic (CTQ) and variation in purity level of water are addressed through the simulation-based LSS approach. All the process parameters and noise parameters of the reverse osmosis (RO) process are optimized to reduce the errors and to improve the purity of the water. The project shows substantial improvement in the sigma rating from 1.14 to 3.88 due to data-based analysis and actions in the process. Eventually, this assists the management to realize an annual saving of 20% of its production and overhead costs. This study indicates that LSS can be applicable even in the advent of I4.0 by reinforcing the existing approach and embracing data analysis through simulation.Research limitations/implicationsThe limitation of this research is that the inference is drawn based on a single case study confined to process industry automation. Having said that, the methodology deployed, scientific information related to optimization, and technical base established can be generalized.Originality/valueThis article is the first of its kind in establishing the integration of simulation, LSS, and I4.0 with special reference to automation in the process industry. It also delineates the case study in a phase-wise manner to explore the applicability and relevance of LSS with I4.0. The study is archetype in enabling LSS to a new era, and can act as a benchmark document for academicians, researchers, and practitioners for further research and development.