Define-measure-analyze-improve-control Approach Research Articles

Enhancing Fuel Ratio Efficiency for Sustainable Operations in Pit KX Mining: DMAIC Methodology

PT ABC is one of Indonesia’s largest coal mining businesses, and the mining. Pit KX is one of the company’s pits worked by contractors, and it has been mined since 2008. According to the company’s historical data from January 2022 to June 2023, overburden and coal production from Pit KX has decreased while fuel consumption has grown. Fuel is a major cost component in mining operations. The overall fuel cost represents around 35% of the company’s total operational cost. This study investigates the use of the DMAIC (Define, Measure, Analyze, Improve, Control) approach as a systematic framework for improving fuel ratio efficiency and promoting sustainable practices in pit KX mining operations. The DMAIC technique provides a disciplined pathway for discovering, assessing, and eliminating fuel-related inefficiencies. DMAIC offers a disciplined framework for improvement. By implementing DMAIC methodology, it can systematically identify and address inefficiencies in fuel utilization leading to reduced operational costs, minimized environmental impact, and enhanced sustainability of pit KX mining operations.

Reduction in Average Length-of-Stay in Emergency Department of a Low-Income Country's Cancer Hospital.

Prolonged length of stay (LOS) in emergency departments (ED) is a widespread problem in every hospital around the globe. Multiple factors cause it and can have a negative impact on the quality of care provided to the patients and the patient satisfaction rates. This project aimed to ensure that the average LOS of patients in a tertiary care cancer hospital stays below 3 hours. The Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) approach was followed. The average LOS was 166 minutes before implementing interventions. The two primary reasons for the increased length of stay were delays secondary to physician assessment and diagnostic lab reports. Strategies were defined to control these factors, which helped reduce the average length of stay to 142 minutes, a 30% reduction. A process improvement model similar to this project is recommended to enhance the quality of hospital services. It will provide valuable insights into the process flow and assist in gathering precise data on the various steps involved. The data collected can then be analyzed to identify potential causes and make informed decisions that can significantly improve hospital processes.

Sustainable Lean Six-sigma: A new framework for improve sustainable manufacturing performance

Sustainable Manufacturing is essential in supporting a more sustainable production process in the current era. However, continuous improvement research that utilizes Manufacturing Sustainability Index (MSI) scores in improving Sustainable Manufacturing performance is still limited. Therefore, this study aims to propose a new framework for evaluating Manufacturing Sustainability based on lean Six Sigma and Sustainable Manufacturing concepts using Sustainable Value Stream Mapping (Sus-VSM). We call this new framework Sustainable Lean Six-sigma (SLSS) based on the DMAIC (Define, Measure, Analyze, Improve, Control) approach. The SIPOC diagram and the Delphi method are used in the Define stage to select relevant indicators. Then, the selected indicators were evaluated in the Measure stage, and the Manufacturing Sustainability Index (MSI) was calculated. At the Analyze stage, the Sus-VSM is analyzed. At the Improve stage, improvement proposals are made using Failure Mode and Effect Analysis (FMEA), and a future Sus-VSM is created. Finally, in the Control stage, check sheets are created to control the implementation of the proposed improvements. In the DMAIC process, Sus-VSM is used as a production flow mapping using a traffic light system to map indicators in each process and MSI values on the production line. A case study was also conducted on the Agro-Food Industry. The results showed that the proposed framework could be implemented in the company and successfully improved the Manufacturing Sustainability Index (MSI) score from 88.78% to 93.80%. The implication of this research shows the potential of using the SLSS framework in improving manufacturing sustainability performance in industrial sectors.

Efforts To Improve the Quality of Welding Plastic Pallet Type HDX1210R With Six Sigma Method at PT. Pallets

PT. Pallets is a manufacturing company that processes plastic waste into products that have value, namely plastic pallets. A plastic pallet is a flat city-shaped container used as a base for storing and transporting goods in logistics warehousing. This study aims to improve the quality of plastic pallet welding products of the HDX1210R type at PT. Pallets. This study uses the Six Sigma method with the DMAIC (Define - Measure - Analyze - Improve - Control) approach with the help of fishbone diagrams, Pareto diagrams, and FMEA. From the company's historical data from March 2022 to March 2023, 3 types of defects were obtained, with loose welding as the highest type of defect, with a percentage of 89% of the total product defects. The overall DPMO average value is 49908.1405, and the average sigma value is 3.191. From FMEA calculations, the highest RPN value is obtained for frequently changing over machines with a scale value of 480. The proposed improvements can be made by changing the hitter model and size, modifying the mold (pallet molding) by adding the welding area on the pallet and making SOPs for producing HDX1210R-type pallet welding.

Enhancing Embankment Stability Assessment in Mining Operations through Fiber Optic Instrumentations: A DMAIC Approach

This paper proposes a comprehensive solution to enhance embankment stability assessment in mining company's tailings management operations through the implementation of Fiber Optic instrumentations. The current monitoring solutions lack real-time capabilities, hindering timely assessment and mitigation of embankment stability issues. Fiber Optic cables provide sensing capabilities to detect vibrations and measure temperature variations, enabling early detection of structural issues within embankments. Real-time monitoring allows continuous assessment and immediate identification of potential risks. Implementing fiber optic cable instrumentations enhances embankment stability assessment, ensuring safety and minimizing failures. Data-driven decision-making is empowered through accurate and real-time data, enabling efficient resource allocation. The implementation follows a DMAIC (Define, Measure, Analyze, Improve, Control) approach, ensuring a comprehensive analysis and step-by-step plan. In conclusion, fiber optic cable instrumentations offer valuable enhancement to embankment stability assessment in mining's tailings management operations. Real-time monitoring, accuracy, and precision contribute to proactive measures and improved decision-making. Implementing this solution strengthens embankment stability practices, safeguards surrounding areas, and maintains regulatory compliance, fostering resilience and sustainability in mining operations.

Six Sigma Approach to increase the Original equipment percentage in hinoline

Rejection Analysis is a process of identification of quality and productivity related problems which are the key factors in manufacturing process. It provides effective suggestion to the problem encountered in manufacturing process. It was apparent that production line was having more defect and rework and had rejection percentage rate. In this project we examine the cylinder liners, analysis and study was conducting to observe the process going in the production line, to increase the OE percentage of cylinder liners by tracing the root causes and by providing suggestion. It is also a process of continuous improvement that gives better results every time when implemented properly. In this project we are approaching six sigma to reduce the rejections. This paper discusses the implementation of Six-sigma methodology in reducing defectives in a cylinder liner manufacturing industry. The Six- sigma DMAIC (define– measure– analyze –improve – control) approach has been used to achieve this result. This paper explains the step-by-step approach of Six-sigma implementation in this manufacturing process for improving quality level.

Implementation of Lean Manufacturing for Increasing the Quality of Aluminum Conductor Products in the Stranding Process with the DMAIC and VSM Method Approach: A Case Study in Electrical Manufacturing Component

ElectricalCompany in this study is a manufacturing company engaged in the cable industry and one of the products it produces is an aluminum conductor. The current situation shows that the quality of aluminum conductor products still does not meet thecompany's standards. This can be seen from the production output data for the period June 2021 –November 2021 where the percentage ofaluminum conductor product faiuresexceeds the set target of 1.50%. The purpose of this research is to implement lean manufacturing to improve the quality of aluminum conductor products using the DMAIC (Define, Measure, Analyze, Improve, Control) and VSM (Value Stream Mapping) methods. The expected result of this research is an increase in product quality.

1009. Integrating a Lean Six Sigma DMAIC approach to improve transitions of care in patients discharged on outpatient parenteral antimicrobial therapy

Abstract Background Outpatient Parenteral Antimicrobial Therapy (OPAT) programs aim to facilitate early discharge and improve patient care; however, rates of readmission remain high. After discharge, safe monitoring and follow-up is logistically heterogenous and prone to error. We aimed to utilize a Six Sigma framework to evaluate our OPAT process and define opportunities for improvement in patient care. Methods A define, measure, analyze, improve, control (DMAIC) approach was used by a multidisciplinary group to evaluate errors and opportunities in the OPAT discharge process (Fig 1). Baseline analysis of 6-months of OPAT discharges revealed an all cause 30-day readmission rate of 19.7%, and less than half of all patients (45%) were seen in the infectious diseases (ID) clinic within 28-days. The group created a process map and identified potential opportunities for error and heterogeneity in the process. A define, measure, analyze, improve, control (DMAIC) approach was used by a multidisciplinary group to evaluate errors and opportunities in the OPAT discharge process Results Process mapping revealed process heterogeneity depending on patient discharge location (Fig 2). Reliability of ordering labs and transporting patients to appointments varied by location (Skilled nursing facility (SNF) versus home infusion, etc.). Furthermore, the OPAT note was not included in the discharge summary and the process was reliant on an ID team member emailing the clinic to request follow-up. An Ishikawa diagram identified numerous factors contributing to OPAT related adverse events (Fig 3). Main opportunities for improvement included (1) the OPAT note, (2) delegation of laboratory ordering for monitoring patient after discharge, (3) patient follow-up scheduling and monitoring, and (4) skilled nursing facility (SNF) communication and expectations. Interventions resulting included working with information technology to update the OPAT note to include appointment dates, attaching OPAT note to discharge summary, and bridging communication and ensuring task completion by delegating certain reliable SNFs as centers of excellence. Process mapping revealed significant process heterogeneity depending on patient discharge location, that the OPAT note was not included in the discharge summary, and the process was heavily reliant on an ID team member emailing the clinic to request follow-up and ensure future laboratory tracking. An Ishikawa diagram identified numerous factors contributing to OPAT related adverse events including numerous system and individual factors Conclusion The DMAIC approach was useful in identifying opportunities to improve transitions of care in patients discharged on OPAT and developing interventions for targeted process improvement. Other centers may use a similar strategy to analyze and improve the care of OPAT patients. Disclosures All Authors: No reported disclosures.

Six sigma DMAIC approach based mobile application for statistical analysis of COVID-19 data

PurposeCoronavirus disease 2019 is one of the novel diseases formed by a dreadful virus called Severe Acute Respiratory Syndrome Coronavirus 2. Various countries are affected by this viral disease, and many countries declare a lockdown with several rules and conditions. To prevent this rapid viral transmission, various researchers have introduced different mobile applications. This paper aims to study issues like viral transmission, mortality rates, vaccination rates, etc. and also provides suitable solutions based on the statistical analysis with the assistance of the Six-Sigma Define-Measure-Analyse-Improve-Control (DMAIC) concept.Design/methodology/approachStatistical analysis is done for different countries, and the required solutions are provided by using the DMAIC procedure. This application has the ability to represent the current risk status of the user and notify them to secure themselves.FindingsThe proposed work suggests the Aarogya Setu application to prevent large viral transmission by affording many preventive measures. This application also issues the current risk status of each individual user. Hence, it gives improved results in avoiding high viral transmission.Originality/valueThe proposed six-sigma DMAIC concept also affords the control measures to prevent viral transmission. Hence, the suggested application has the highest chance of avoiding the rapid viral transmission.

Six Sigma for improving tensile strength: a case study in the impregnating resin manufacturing company

PurposeUnsatisfactory level of construction materials quality has been a persistent problem for companies in construction. This study aims to describe the application of the Six Sigma methodology for improving the tensile strength in a Chinese reinforcement material manufacturing company.Design/methodology/approachSix Sigma-based framework of define-measure-analyse-improve-control (DMAIC) methodology is adopted in this case study. During different stages, quality problems and critical factors are identified to improve the low performance of tensile strength and thixotropy of the impregnating resin.FindingsThe results provide solid evidence that how Six Sigma can be successfully applied in reinforcement material manufacturing. Results showed that vacuum degree, reaction temperature and stirring rate are significant factors on tensile strength. Control plans for continuous improvements are suggested and implemented. Our study found that managerial assurance activities such as verification were less developed than equipment-related control activities. Besides, data management required further elaboration on integrated data and information systematically, thereby to enable the company to make informed decisions and to support continuous improvement.Originality/valueThis study contributes to show a potential area in which Six Sigma DMAIC approach can promote to improve the tensile strength of impregnating resin. This case can prompt managers of the company to apply Six Sigma method to address complicated problems in other reinforcement material processes. Companies of construction and their suppliers can refer to this study when improving their manufacturing process.

Solving production bottleneck through developed define-measure-delegate-implement-control in solving production bottleneck

This study focuses on the development of a define-measure-delegate-implement-control (DMDIC) framework to solve production bottleneck where this issue causing the productivity to drop. The plan-do-check-act (PDCA) and define-measure-analyse-improve-control (DMAIC) approaches have been successfully employed in solving production issues, however each approach has its limitation to certain aspects, for example, both approaches dealing either short- or long-term solution. The PDCA approach normally proposes a short-term solution that is faster in achieving a result. While the DMAIC approach can propose a long-term solution that can find the main causes of the drop in productivity. Thus, this study introduces a newly developed framework on handling short- and long-term solution to improve production bottleneck. Based on the simulation results using DMDIC approach, the production daily output had significantly improved from 264 to 304 units which had met customer daily demand. This result showed that the developed framework could improve productivity, thereby meeting customers' requirements.

Design of Lean Six Sigma to Reduce Waste in Aerophile Line Production Processes in The Chemical Industry Using DMAIC And VSM Approach

This research was conducted on companies engaged in the chemical industry which are manufacturers of household products such as: air freshener, baby care products, food plastic wrappers, metal polishers, mouse glue, insecticides, lpg cans, car care products, insect repellent, and many more. many other products. The product chosen to be used as research material this time is an aerosol insect repellent product. This research was carried out in the production department of an aerophile line that produces aerosol insect repellents. This study aims to determine the defects and waste that occur in the aerophyll line so that it can improve quality and increase the amount of production in order to meet customer desires. The method used in this research is descriptive which is done by analyzing the production process of one type of product on the aerophile line by observing for 3 months. The results of this study were carried out using the DMAIC (Define, Measure, Analyze, Improve, Control) and VSM (Value Stream Mapping) methods identified 5 types of defects, namely dented cans, missing batch numbers, reject caps, leaks, and low weight. From the calculation results, the average DPU is 0.05, the average DPO is 0.01, the average DPMO is 10278.14, the average production yield is only 68.59% and the level of sigma value is at level 2. Improvements made with Lean Sigma by expanding the capacity of the waterbath and accelerating the process of immersion and raising the temperature in the waterbath, scheduling machine inspections, making checksheets, and work instructions and SOPs. So that we get a decrease in production cycle time from 88 minutes to 83 minutes which has an impact on increasing the production target from 72 pallets/day to 78 pallets/day, and has an impact on the actual number of production from 1,875 pallets/month to 2,028 pallets/month.

ANALISA PENGENDALIAN KUALITAS PRODUK KERAMIK LANTAI DENGAN MENGGUNAKAN METODE SIX SIGMA DI PT. PRIMARINDO ARGATILE

Quality control is a management activity to measure the quality characteristics of existing products, compare them with specifications or requirements, and take appropriate action if there is a difference between the actual appearance and standardization. The purpose of this research is to solve the causes of defective product problems that occur with the DMAIC (Define, Measure, Analyze, Improve, Control) approach to the Six Sigma method. This study uses a qualitative approach. This study analyzes defective products using the Six Sigma method in order to minimize defective products in the kiln area. Based on the research discussion, the dominant product defect is the sample in the kiln area. It is known that there are five types of product defects that can cause defective products, namely body burst by 22%, sag by 10%, preheating crack by 4%, glaze crack by 20%, and sompel by 40%. And based on the results of calculations carried out the company is at the level of six sigma 3.36 sigma

Operational Improvement in Infrastructure Department Contract Service Performance in Coal Mining Company

Infrastructure is defined as the physical facilities that provide the primary support for carrying out an organizational business process. Infrastructure includes all technical aspects and facilities required to keep an organization's operations or business processes running smoothly. Infrastructure facilities are considered to all facilities related to an office building, road, water treatment plant, water distribution, airport, building and office, drainage, reservoir, bunding, retaining wall, bridge, sewerage treatment plant, power distribution, power plant, telecommunication, fuel facilities, fuel distribution, housing, port and jetty, and other facilities that support the operational activities of an organization's business process. PT. Kaltim Prima Coal considers the service level in maintenance activities that are related to the compliance performance in quality service, lead time, and work completion performance. These are some of the performance indicators used to measure the Infrastructure Department's agreement for contract maintenance. An operational strategy improvement in infrastructure department contract service maintenance is expected to improve the service level, shorten the lead time and increase customer satisfaction in order to meet the performance indicators. Six-Sigma – DMAIC (Define-Measure-Analyze-Improve-Control) approach is implemented to overcome the service level compliance problem in infrastructure operational maintenance service. Six Sigma has proven to be effective in reducing quality defects, eliminating variation, and significantly increasing the organization performance. The major issue will be investigated using fish bone analysis to determine the root cause and optimize the operational maintenance activities and increase the service level performance from 84 percent average to 100 percent.

A Six-Sigma DMAIC Approach to Improve the Sales Process of a Technology Start-Up

Despite the adoption of Six-Sigma in different service sectors, its application in the Sales function of a Technology-based Start-up has not been explored. This paper deploys an action research-based study methodology and conducts a thorough analysis of a Technology Start-up company in Indonesia, using Six-Sigma principles and the Define-Measure-Analyse-Improve-Control (DMAIC) approach. Statistical validation of the causes of problems helped to formulate a strategy that may have otherwise not been possible. The results of the study and proposed solutions confirm the potential benefits of adopting Six-Sigma in the Sales function of technology start-ups to reduce, particularly, customer waiting time. The novelty of this research lies in the fact that it applies Six-Sigma in a transactional process such as sales, which earlier studies have not explored in depth. This paper can be employed as a reference for organisations to undertake and guide specific process improvement projects similar to the one presented.

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.

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.

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...

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.

Lean Six Sigma competitiveness for micro, small and medium enterprises (MSME): an action research in the Indian context

PurposeThe aim of the article is to ascertain the challenges, lessons learned and managerial implications in the deployment of Lean Six Sigma (LSS) competitiveness to micro, small and medium Enterprises (MSME) in India and to establish doctrines to strengthen the initiatives of the government.Design/methodology/approachThe research adopts the Action Research methodology to develop a case study, which is carried out in the printing industry in a Tier III city using the LSS DMAIC (Define-Measure-Analyze-Improve-Control) approach. It utilizes LSS tools to deploy the strategy and to unearth the challenges and success factors in improving the printing process of a specific batch of a product.FindingsThe root cause for the critical to quality (CTQ) characteristic, turn-around-time (TAT) is determined and the solutions are deployed through the scientifically proven data-based approach. As a result of this study, the TAT reduced from an average of 1541.2–1303.36 min, which in turn, improved the sigma level from 0.55 to 2.96, a noteworthy triumph for this MSME. The company realizes an annual savings of USD 12,000 per year due to the success of this project. Top Management Leadership, Data-Based Validation, Technical Know-how and Industrial Engineering Knowledge Base are identified as critical success factors (CSFs), while profitability and on-time delivery are the key performance indicators (KPIs) for the MSME. Eventually, the lessons learned and implications indicate that LSS competitiveness can be treated as quality management standards (QMS) and quality tools and techniques (QTT) to ensure competitive advantage, sustainable green practices and growth.Research limitations/implicationsEven though the findings and recommendations of this research are based on a single case study, it is worth noting that the case study is executed in a Tier III city along with novice users of LSS tools and techniques. This indicates the applicability of LSS in MSME and thus, the modality adopted can be further refined to suit the socio-cultural aspects of India.Originality/valueThis article illustrates the deployment of LSS from the perspective of novice users, to assist MSME and policymakers to reinforce competitiveness through LSS. Moreover, the government can initiate a scheme in line with LSS competitiveness to complement the existing schemes based on the findings of the case study.