DMAIC Approach Research Articles

Analisis Pengendalian Kualitas dalam Upaya Meminimalisasi Tingkat Kerusakan Produk Gula Rafinasi

ABSTRACT Non-conformance to products is produced due to unavoidable production processes. However, it can be minimized in terms of potential occurrences as well as providing a solution to achieve a minimum level of mismatch. This study aims to identify the percentages and types of discrepancy experienced by the company, analyzing process capabilities and identify underlying factors in discrepancy. The research has been done in May 2018. The reseach was implemented in lab and department of process at PT Sugar Labinta, Tanjung Sari, Lampung Selatan. The use of the six sigma method with a structured DMAIC approach is definie, measure, analyze, improve, and control. The tools used in six sigma program on this research consisted of check sheet, caused diagram, p-control chart, and Pareto diagram. It’s processed through the software Minitab 18. The results showed the level sigma process in PT Sugar Labinta 5.04 and has a value DPMO 238.32 based on the table of achievement Sigma defined that the company is at the average level of the USA industri, then to be able to reach the level of Sigma 6 , the discrepancy in respect of the product does not exceed 8 tonnes per month.

ANALISIS PENGENDALIAN KUALITAS PROSES PENGANTONGAN SEMEN MENGGUNAKAN SIX SIGMA (STUDI KASUS PT. SEMEN BOSOWA BANYUWANGI)

The cement bagging process at PT Semen Bosowa Banyuwangi is still done simply using a check sheet. The percentage of defective products based on observational data on January 10-February 5 2020 is 0.39% which is at the four sigma level (4σ). This study focused on controlling the quality of the Bosowa Cement bagging process using the Six Sigma method with the DMAIC approach (Define, Measure, Analyze, Improve, Control) which aims to help control the quality of cement bags by reducing the number of defective products to reach the six sigma level (6σ). By using the tools CTQ, P-Chart, Sigma Level, Pareto Diagram, Fishbone Diagram and FMEA, the potential causes of damage that often occur 
 diverter valve is problematic, and the position of the bag is stuck. saddle bag is not precise. Based on the cause of the damage, a solution was found in the form of routine preventive maintenance on each equipment in the packer area and inspections and sampling tests for the quality of the cement bags to be used.

Application of six sigma and 5 S to improve medication turnaround time

ABSTRACT Purpose: The purpose of this study is to improve the medication turnaround time of a tertiary care hospital in Bangalore. The goal for improvement was set as 1 h based on the voice of external and internal customers and benchmark of two studies where the improvement results were 70 min and 66 min. Background: There is documentary evidence that timely administration of medicines such as antibiotics results in a significant decrease in mortality and length of stay. The increased length of stay increases the cost of treatment for the patients and reduces the bed turnover rate for the hospital. Method: DMAIC approach of Six Sigma together with the ‘Seiton’ principle of 5 S quality tool is used to reduce the medication turnaround time and to improve the sigma level of the process. Results: At the end of the study the mean total turnaround time of 1 hr 29 min got reduced to 48 minutes and the sigma level got improved from 1.22 sigma level to 2 sigma level. Conclusion: This study showcases that Six Sigma and 5 S can be used effectively to reduce the medication turnaround time, which enables in achieving the long term goals of patient satisfaction.

Green Lean Six Sigma for sustainable development: Integration and framework

The sustainable oriented demand, globalized competition, and governmental policies on climate change have enforced the industries to adopt sustainable practices. Green Lean Six Sigma (GLS) is an eco-friendly approach that mitigates carbon footprints and produces high specifications products. But to implement the GLS program, it is indispensable to integrate individual Green, Lean, and Six Sigma approaches in unique GLS methodology. Moreover, there exists no GLS framework that can be applied irrespective of the size, type, and culture of the organization. So, the present work deals with the integration and development of the GLS framework. The integration of the GLS was proposed based on theoretical elements, and the framework was developed based on DMAIC approach. It has found that enablers, toolset, and implementation methods supplement the integration of GLS. The proposed framework provides a path for GLS implementation through an appropriate selection of the project. Besides, it has identified that unique GLS indices and toolset are required to estimate various sustainability measures and execute selected GLS projects. The present study will facilitate the organizations to have readiness for the implementation of a sustainable GLS approach through a detailed understanding of integration and GLS framework.

Reducing soldering defects in mobile phone manufacturing company: A DMAIC approach

A DMAIC (an effective tool) approach has been presented in this paper for reducing defects in soldering in an endeavor to approach six sigma quality level in a mobile phone manufacturing company. DMAIC helps expose and kill the root causes of defects in the process and thereby helps achieve higher customer satisfaction by means of improved quality. The case study was conducted in an electronics manufacturing industry engaged in an assembly of mobile phones. Post successful implementation of Six sigma - DMAIC in the assembly processes, ppm defectives dipped from 3800 to 200, which is a massive 94.74 percent reduction in ppm defectives.

The Productivity Performance's Measurement in SME Industry by using DMAIC of Six Sigma

It is crucial that Malaysia’s Small- Medium Enterprises (SME) in the manufacturing sector could achieve desired productivity rate as this could contribute not only to the country’s Gross Domestic Product (GDP), but also could contribute to the spending power of a nation. It is important for SME manufacturers to stay ahead in the ever-competitive market to ensure their survival and provide countless jobs for the nation. The objective of this paper is to study, analyse and propose viable solutions to improve manufacturer performance in terms of productivity and quality in the manufacturing sector by using various operation management tools. Hence, one SME company was chosen by utilizing the Value Stream Mapping (VSM) in DMAIC approach to measure their productivity. The aerosol production line was study, to see the gap measurement in productivity before and after applying a systematic method in operation management. Furthermore, along with various operation management tools such as Kaizen, Kanban system and 5S, a new layout (VSM) for the production line was proposed. Result shows that the proposed new layout could reduce the distance travelled by operator by 22.26 %, at the same time will increase the productivity and quality of product. Since the overall performance of the aerosol grease production line will be improved, the waste found in the production line also will be alleviated

Materials selection of “green” natural fibers in polymer composite automotive crash box using DMAIC approach in Six Sigma method

This article presents the results of research in selecting the most appropriate natural fibers to be used as reinforcement (normally in the hybrid form) in polymer composites for the automotive crash box by carrying out the materials selection process using the Six Sigma method. The judgment based on results from Six Sigma integrated two decision methods, which were applied using two different approaches in decision making: qualitative method and quantitative method. In this study, oil palm fiber had been proposed as the most appropriate natural fiber to be selected as reinforcement in composite automotive crash box. The DMAIC approach from the Six Sigma method performed an important role by providing various tools for each phase in the material selection process. The final selection process led to selection of oil palm fiber as the best natural fiber to reinforce polyurethane as polymeric matrices due to the satisfaction of all the selection criteria.

Lean Six Sigma implementation in an OEM: a case-based approach

Lean Six Sigma (LSS) is a successful quality improvement program. However, many pieces of literature have reported that companies have struggled with LSS projects and Indian manufacturing firms are no exception to this scenario. Therefore, this article describes LSS implementation at a manufacturing company. The company manufactures power take off (PTO) shafts for tractors. Nevertheless, the company was receiving high non-conformance resulting in part rejection. Therefore, the study deals with the defect reduction through LSS implementation. Using the DMAIC approach with suitable tools, statistical analyses were performed to identify the bottleneck in the operations, and the corrective measure was taken to improve the quality of PTO. In addition, the researchers proposed preventive methods for reoccurring issues and developed a plan to sustain the project to find the required results. At the end of the project, the researchers yielded considerable cost saving and defect reduction. The study concludes with the managerial implications and contribution to the society with the limitations of the study.

Productivity enhancement in engine assembly using lean tools and techniques

Lean assembling is bound together with a framework that is involved with a lot of ways of thinking, rules, instruments and strategies, which whenever forced, take out critical burn through and loss of time in all business formats for constant enhancement. But very scarce explorations about lean manufacturing implementation have been done in automobile industry. This paper represents the productivity enhancement using basic lean manufacturing tools in engine assembly at Renault Nissan Automotive India Private Limited Coimbatore. This paper highlights a methodology developed for standardization and improvement in the process of engine assembly activities using lean manufacturing tools and techniques line by using DMAIC approach. Productivity enhancement is the primary goal which is to be achieved for any profitable manufacturing system. All this initiated by performing study on the manual operator’s activities. For an engine assembly processes the tools description, process description and existing sheets were studied which provided detailed information about all the movements of assembly activities.

Lean Six Sigma implementation in an OEM: a case-based approach

Lean Six Sigma (LSS) is a successful quality improvement program. However, many pieces of literature have reported that companies have struggled with LSS projects and Indian manufacturing firms are no exception to this scenario. Therefore, this article describes LSS implementation at a manufacturing company. The company manufactures power take off (PTO) shafts for tractors. Nevertheless, the company was receiving high non-conformance resulting in part rejection. Therefore, the study deals with the defect reduction through LSS implementation. Using the DMAIC approach with suitable tools, statistical analyses were performed to identify the bottleneck in the operations, and the corrective measure was taken to improve the quality of PTO. In addition, the researchers proposed preventive methods for reoccurring issues and developed a plan to sustain the project to find the required results. At the end of the project, the researchers yielded considerable cost saving and defect reduction. The study concludes with the managerial implications and contribution to the society with the limitations of the study.

Pengurangan Aktivitas Non-Value AddedDalam Alur Proses Pelayanan Kesehatan Dengan Pendekatan Lean Six Sigma

Purpose- This study aims to reduce Non-Value Activities in the Health Service Process flow using Lean Six Sigma Approach in the Outpatient department of LubukBuaya Health Center.Methodology - The research reported in this paper is based on a case study carried out using the lean six sigma DMAIC (Define-Measure-Analyze-Control) approach and its application in to reducing non-value activities in the health service process flowin the outpatient department of LubukBuaya health center in Padang. The analytical tools used in this study include value stream mapping, process capability, and fishbone diagram.Finding - From the results of the analysis and research that has been done it turns out thatThe lead time needed in the flow of the outpatient service process is 82.74 minuteswith percentage of process cycle efficiency is 15,03%, it means that the service process to the outpatients is not yet efficient. It is caused by several factors such as there is no online registration application, the number of visits increases at certain hours, and use of the patient's electronic database that is not optimal. Keywords: Reduce, Non-Value Activities, Lean six sigma, DMAIC, Health service, Outpatient.

Collaboration with commercial payor to eliminate prior authorization.

9 Background: For commercial insurance plans, there is often a requirement to obtain prior-authorization for specific services. Prior-authorization though intended to ensure medical necessity, can cause significant delays in patient care and create an unnecessary administrative burden. It often leads to undue anxiety in patients, dissatisfaction among providers and substantial waste in the system. To increase our efficiency and improve patient and provider experience, we partnered with one of our region’s largest commercial payors to eliminate prior-authorization. Methods: A Lean Six-sigma DMAIC approach was adopted: Define- created a process map. Measure- calculated baseline for prior-authorization denials. Analyze- conducted retrospective analysis to identify areas to improve. Improve- conducted provider training for appropriate imaging guidelines. Control- established internal auditing to check provider compliance. Results: At SCCA, we found that 94.8% of prior-authorizations were approved instantly or after providing more documentation, thus prior-authorization did not add value. Moreover, 2.15% were approved after peer-to-peer review that involves significant administrative burden and delay in care. Only 3% prior-authorizations did not meet medical necessity criteria, major reasons being- PET/CT and CT CAP ordered in combination, or PET/CT ordered without clear justification. 2.46% prior-authorizations led to a patient receiving a letter of denial. SCCA and the payor agreed to eliminate prior-authorizations for all imaging (except PET and PET/CT). This required all ordering providers to attest to completion of training on the NCCN Imaging Appropriate Use Criteria. In addition, a quarterly internal audit was put in place to check provider compliance to NCCN guidelines for ordering Imaging tests. SCCA achieved a 100% provider training completion rate and 100% provider compliance to NCCN guidelines in the first two internal audits. Conclusions: A strong partnership and shared vision with a payor enabled us to eliminate wasteful prior-authorizations. Our high training completion rate and compliance rate implies strong support from our providers and leadership to provide value-based care to our patients.

Implementation of Six Sigma to Minimize Defects in Sewing Section of Apparel Industry in Bangladesh

The garments industries which are traditionally operated are facing lots of problems such as low productivity, poor line balancing, high rejection, high defects, unable to achieve lead time. So defects minimization is the first condition of reducing cost and increasing productivity. The work aims to minimize the defect percentage by using DMAIC approach of Six Sigma methodology. The study is carried out in Ananta Apparels Ltd. by using DMAIC methodology of six sigma to minimize the defect rate in sewing section. Five phases of the DMAIC methodology named Define, Measure, Analyze, Improveand Control which indicates some critical defects such as stain, skip stitch, broken stitch, and slip out in the sewing section of Ananta Apparels Ltd. We applied various types of six sigma tools in different phases. The outcome of this study is very significant to implement in the sewing section of the apparel industry.

ANALISIS KECACATAN KEMASAN PRODUK OKKY JELLY DRINK PERISA BLACKCURRANT SEBAGAI UPAYA PERBAIKAN KUALITAS DENGAN METODE DMAIC PADA PT. TRITEGUH MANUNGGAL SEJATI

Abstract This study aims to determine and identify the causes of defects in the production process of PT. Triteguh Manunggal Sejati and know the level of sigma level. This research uses the six sigma method with the DMAIC approach as a quality control tool, which includes the Define, Measure, Analyze, Improve and Control stages. Based on this study the results obtained are the level of sigma level at PT.Triteguh Manunggal Sejati is 4.96, which means that in the stage of sigma level the company has not reached the level of six sigma levels because in the production process at PT.Triteguh Manunggal Sejati still has product defects in the production process not yet achieved zero defect. The causes of product defects are based on cause and effect diagrams namely lid / seal defects are leaky lid, broken lid, and tilted lid. Kata kunci : Defect, Six Sigma, DMAIC, cause and effect diagram

Productivity Improvement by Reducing Defects in Turning Process through DMAIC Approach

Productivity Improvement by Reducing Defects in Turning Process through DMAIC Approach

IMPROVING SERVICE QUALITY OF CALL CENTER USING DMAIC METHOD AND SERVICE BLUEPRINT

AbstractCustomer satisfaction is an important factor to businesses, because it causes customers to constantly return to use the service. Customer satisfaction is also related to the quality of service received by the customer of the companys’ products or services. The problem of OC’s call center service quality happened at the first time a customer contacts the call center where waste of customer’s waiting time is detected. Service quality improvement methods used in the analysis of the waste of customers’ waiting time is the DMAIC and lean approach. Results showed that improvement is seen at the sigma level. The tools used are SIPOC, pareto diagram, CTQ, two proportion test, DOE, p-chart, and minitab-16. Service blueprint analysis is used to analyze and discuss the relationship between service quality improvement using DMAIC in service process, points of contact with customers, and the evidence seen by the customer serviceKeywords: service quality, lean, DMAIC, service blueprint, sigma level

DMAIC Approach for Road Wellbeing: A Case Study

The objective of this paper is to implement the DMAIC methodology for finding out the reason for the traffic jam in the NH-24 connecting Delhi, Ghaziabad and Noida and finding out the solution for reducing them. For this survey, we have collected the data of a fixed route for 14 days and implemented various statistical methods for analyzing it. The study, focused on various junctions because these are the points, which are more prone to congestion. It aimed at finding out the critical junction and suggest improvement in them. As the number of vehicles is on the rise, it is the need of the hour to solve this problem

DMAIC Six Sigma Methodology in Petroleum Hydrocarbon Oil Classification

This research focuses on the use of the DMAIC method (Define, Measure, Analyze, Improve and Control) as a Six Sigma approach in studying oil spill fingerprint of samples recovered from Peninsular Malaysia and Sabah (East Malaysia). The DMAIC approach in this study was used as a way to classify oil types based on data obtained from GC-FID and GC-MS measurements. The cause-effect diagram was used to define the factors leading to the failure of the oil spill fingerprinting based on inaccurate oil type clustering. Discriminant Analysis (DA) was also applied to quantify the root-cause of the failure. An Ishikawa diagram obtained in the analysis phase identifies the potential failure causal. Principal component analysis (PCA) was applied and was successful in discriminating four clusters of oil types, namely diesel, heavy fuel oil (HFO), mixture oil lube and fuel oil (MOLFO) and waste oil (WO) with a total variance of 85.3%. In the control phase, the use of a Pareto chart indicated 100% cumulative percentage of oil type clustering with a 95% confidence level. The DMAIC approach to be effective in solving oil spill fingerprinting problems and results in quality improvement in the clustering of oil spills into the different hydrocarbon types.

Evaluating the supply chain information flow in Egyptian SMEs using Six Sigma

Purpose There is a great deal of concern among the Egyptian economy that small- and medium-sized enterprises’ (SMEs’) potentials are not fully used although they dominate it and contribute to its success. The question is what challenges are preventing those SMEs from performing efficiently. This research aims to focus on examining the issues regarding the supply chain of Egyptian SMEs, exploring the areas that need improvement and assessing the impact of technology in enhancing their performance and whether they afford applying it. Design/methodology/approach In this research, semi-structured interviews were conducted at 14 Egyptian SMEs. Then, the business process at six of the fourteen SMEs was observed. After that, a representative sampling was applied and a company was chosen as a representative case company. Moreover, the selected company’s documents were analyzed to capture the full image of the current supply chain performance in Egyptian SMEs. Finally, the Six Sigma DMAIC approach was used to assess the effectiveness of the current supply chain and identify the problems faced and how to deal with these deficiencies. Findings The current process of the supply chain was analyzed and the result shows the obstacles and constrains facing SMEs in Egypt. Despite the clear benefits of radio frequency identification (RFID) technology, Egyptian SMEs still do not use it to solve their problems due to its high cost and their low budgets. However, the investigation concludes that SMEs in particular can benefit from the RFID technology and will be able to pay back the cost of the system applied after a certain period of time that is measured by calculating the breakeven point of having the RFID system against the current situation. As a result, improvements were realized and recommended for the organization. Originality/value This research develops a model that suits SMEs in the Egyptian market. The use of a case study approach with a quality measurement tool, namely, the Six Sigma DMAIC approach, especially after surveying several SMEs, and observing the business process at some of them, makes this a thorough investigation which proves that even SMEs can use the RFID technology despite its high cost that hinders its utilization. Thus, this research helps decision-makers in Egyptian SMEs make better informed decisions and guides them to when will they be able to pay back the cost of the system applied.

Peningkatan Kualitas Semen “X” dengan Metode Six Sigma di Packing Plant PT. XYZ

PT. XYZ is a company engaged in cement packing plant. When the packing process takes place, there are often work process errors that cause product defects. Six sigma is a method used to improve product quality to produce defect-free products (zero defects) using the DMAIC approach (Define, Measure, Analyze, Improve and Control). The purpose of this research is to improve the quality of X cement products and to achieve zero defects during the packing process. Based on the research, it can be concluded that the types of defects found in the packing process are burst bag, stuck bag, out of tolerance bag weight, damaged bag, with the largest type of defect, namely 72.9% bag burst for 50 kg and 68 bag types, 8% for 40 kg bag types which will be prioritized for repairs. Sigma values for the type of bag 50 kg and 40 kg are in the range of values from 3.79 to 4.13σ. So that improvements still need to be made to achieve the 6σ value and to produce a zero defect product.