DMAIC Methodology Research Articles

DMAIC methodology application in bakery for French bread-quality standardization purposes

French bread is one of the food items mostly consumed in Brazil, as well as Brazilian bakeries’ core product. Its growing demand forces bakeries to adopt strategies to speed up the production of Brazilians’ “favorite”, without losing its typical taste and quality. The current study was carried out in a traditional bakery in Araraquara City, São Paulo State. Its aim is to reduce the number of non-conformities in the French bread-production process. The DMAIC cycle was herein adopted as main methodology, although other tools, such as data collection and analysis, brainstorming and Pareto charts, 5W1H and risk mapping, were also used. Results have evidenced that more than 50% of the investigated production was not in compliance due to labor issues, raw material type and the adoption of non-standard processes. Finally, an action plan comprising bakery-intervention proposals was prepared and it evidenced the need of standardizing the used chemical yeast, of training the bakery’s employees and of standardizing the time of each production stage.

The empirical study of gradation of crushed sand concrete properties using six sigma DMAIC methodology

Fine aggregate plays a key role as a filler material in concrete’s fresh and hardened properties. Generally, in Portland cement concrete aggregate occupies 70-85% by weight and 60-70% by mass. In Pakistan, Lawrence pur the sand as the only sand that meets the ASTM standards. But due to heavy transportation costs, it is not cost-effective to use in most parts of the country. The tests were carried out in accordance with ASTM standards, and the concrete mix designed with three water-cement ratios of 0.40,0.45, and 0.50 called for a mixing procedure. At 28 days of curing, an M30 concrete mix comprising five control mixes including parent concrete was evaluated and compared to parent concrete. This experimental work aimed to enhance the fresh and hardened properties of concrete such as the workability of concrete mix, compressive, and flexural strengths by using locally available Jhelum River sand gradation crushed sand (passing sieve #4, the waste product of Sargodha coarse aggregate), s a fine aggregate material. Using six sigma DMAIC Methodology 9 defects in the Jhelum River sand and control mix have been identified and corrective measures were taken to improve the quality of the concrete mix. The results derived from this experimental work show that adding 50% crushed sand in Jhelum River sand increases compressive strength by 27% and flexural strength by 20% which makes it according to ASTM Standards. The use of crushed sand as an alternative to natural river sand efficient and safe material. This control mix also reduces the construction cost by 10% in comparison to lawerancepur sand.

Quality Evaluation of Al-Rasheed Ready Concrete Mixture Plant By Using Six Sigma Approach

The objective of this research work is to evaluate the quality of central concrete plant of Al-Rasheed Company by using Six Sigma approach which is a measure of quality that strives for near elimination of defects using the statistical methods to improve outputs that are critical to customers. The fundamental objective of Six Sigma methodology is the implementation of a measurement-based strategy that focuses on process improvement and variation reduction to reach delighting customers, and then suggesting an improvement system to improve the production of concrete in Al-Rasheed State Contracting Construction Company. A field survey includes two parts (open and close questionnaire) that aimed to get the data and information required for achieving the research where the answers of questionnaire sample have led, during the application of DMAIC improvement cycle, to identifying the potential possible reasons that caused quality deviations in concrete works. Two programs have been used: First, ‘Sigma Level Calculator’ which is formulated by the researcher to measure the components of the processes performance. Second, ‘QI Macros Lean Six Sigma SPC Software 2011’ which uses the statistical tools of Six Sigma DMAIC methodology for: identifying the root causes of defects, analyzing the data, determining capability and stability of process. It is concluded that the processes sigma level for the concrete works quality is 2.41 σ and 181,070 DPMO which is considered too bad as compared with the current global competitio

Proposed Improvement of the Contract Award Process in Contracting and Procurement using Lean Six Sigma Methodology (A Case Study of an Oil and Gas Company in Indonesia)

Oil and gas (O&G) production is crucial for Indonesia’s economy, and Company XYZ is actively involved in O&G exploration and production in three operational fields. Effective contracting and procurement procedures are essential for timely access to equipment, services, and materials while minimizing costs, delays, and risks. O&G procurement involves various responsibilities such as procuring drilling rigs, equipment, seismic services, and transportation. Insufficient planning in these processes can lead to project delays, increased expenses, and lower profitability. To address these challenges, the research proposes implementing Lean Six Sigma principles with the DMAIC methodology to improve the contracting and procurement process. In the Define phase, the current state of the contract award process is identified through process mapping. The Measure phase evaluates the internal contract routing approval performances, highlighting variations in completion time for IRS documents. The Analyze phase identifies factors contributing to redundancy, including lack of digitization, absence of a contract control system, time-consuming processes, and a complicated routing process. The Improve phase recommends three solutions: implementing a contract monitoring and control system, streamlining the contract approval routing process, and digitizing the contracting and procurement processes. These solutions aim to improve efficiency, coordination, and decision-making, ultimately enhancing the contract award process, reducing delays, and increasing operational effectiveness and profitability. The Control phase ensures the sustainability of proposed solutions through regular monthly reviews to assess the effectiveness of the control plan and make necessary improvements.

APPLICATION OF THE DMAIC METHODOLOGY TO IMPROVE THE PERFORMANCE OF THE PRODUCTION LINE OF A COSMETICS INDUSTRY

Through the high competitiveness of the market and the high level of customer demand, companies sought opportunities to modernize their processes in order to offer quality products and services, with high flexibility and innovation content with lower cost and shorter delivery time. This research seeks to reduce the cycle time of the filling process of a cosmetics industry. For this, the DMAIC methodology was used to map the flow, measure and classify its variables, analyze the data to identify the root cause, propose improvements to the process and manage the performance indicators during the development of the activities. In order to achieve the proposed desires, this research relied on the application of the concepts and tools addressed by Lean Six Sigma. Based on the results, it was seen that there was a reduction in cycle time of 14.86%, where the current state that was 64.74 seconds became 55.12 seconds in the future state.

Engaging Lean Six Sigma Approach Using DMAIC Methodology for Supply Chain Logistics Recruitment Improvement

The purpose of this research paper is to demonstrate the adaptability of lean six sigma using the DMAIC method in reducing the time spent on recruiting new employees for the Supply Chain Logistics Department. Six Sigma is a data-driven, disciplined technique and methodology for reducing defects in any phase, to achieve six standard deviations between the mean and the closest design limit, as modeled by the DMAIC method (Define, Measure, Analyze, Improve, and Control). DMAIC is a method for optimizing, improving, and securing business processes and designs. The DMAIC improvement phase is a key component of Sig Sigma tools. The study focuses on the time spent in the recruiting process of new hires for the supply chain logistics site. The recruiter was interviewed to gather secondary data. Using the Lean Six Sigma DMAIC approach, process efficiency has increased, processes have become faster, and data is more easily accessible. Following the implementation of improvement solutions, the time from the improvement stages can be reduced with the current process using lean six sigma approaches. The company was able to make significant improvements by utilizing its lean six sigma implementation skills, saving time and money while improving quality. The study evaluates prior research and makes recommendations for future research.

Enhancing sustainability performance of universities: A DMAIC approach

AbstractThis paper aims to assess and improve the sustainability performance at a higher educational institute (HEI) in UAE using DMAIC methodology, considering five sustainability aspects (knowledge, behaviour, concern, awareness and attitude). One primary and six secondary research questions were defined in the define phase. In the measure phase, a questionnaire was designed to measure the current sustainability level based on the five sustainability aspects. A questionnaire was distributed among campus populations and statistically analysed in the analysis phase. Participation in UI GreenMetric was used in the control phase to monitor the performance from 2018 to 2020. It was found that the communication college has the lowest sustainability level at 25% marginal error compared with other colleges. Also, students have the lowest sustainability level compared with faculty and staff at a 15% marginal error. The proposed framework can help HEI decision‐makers assess their sustainability levels and suggest plans to enhance sustainability performance.

The performance improvement analysis using Six Sigma DMAIC methodology: A case study on Indian manufacturing company

The six-sigma methodology has been adopted by the industry as a business management tool to improve operational capabilities and reduce defects in any process. This study aims to present a case study on the implementation of the Six-Sigma DMAIC methodology with the purpose to reduce the rejection rate of rubber weather strips manufactured by XYZ Ltd. (name changed) situated in Gurugram, India. Weather strips are used in all four doors of cars for noise reduction, waterproofing, dust proofing, soundproofing, windproofing, and for improving air conditioning cooling, and heating effects. The overall rejection rate of both front and rear door rubber weather strips was 5.5% which was causing a huge loss to the company. The average rejection rate of rubber weather strips per day reduced from 5.5% to 3.08%. After implementing the Six-Sigma project findings the rejection was reduced from 153 pieces to 68 pieces helped the industry in saving the cost of a compound by Rs. 15,249 per month. The sigma level improved from 3.9 to 4.45 within three months with the implementation of one Six-Sigma project solution. The company was highly concerned about reducing the high rejection rate of rubber weather strips and decided to deploy Six Sigma DMAIC as a quality improvement tool. The industry was keen to reduce this high rejection rate to 2% and this target was materialized with the application of the Six-Sigma DMAIC methodology. The novelty of this study is to analyze performance improvement considering the Six Sigma DMAIC methodology to reduce the rejection rate of rubber weather strip manufacturing companies.

A new master degree program in lean manufacturing technologies

Increasing productivity and operational effectiveness can be realized by professional managerial approach. The article considers the current lean manufacturing and production management education providers and find the necessary points for successful operation management realization. Also it is proposed the interaction between the university and industrial partners in order to build and update the education content, participate in the classes and enrich them with industrial cases and guarantee the future career for the students. Lean manufacturing education is based on DMAIC methodology and proper using of Quality Management methods for continuous improvement of organizations. This long-term program provides professional growth for the employees and build their improvement projects sustainable.

Deployment of Lean Six Sigma DMAIC methodology to improve productivity of a can manufacturing industry

Deployment of Lean Six Sigma DMAIC methodology to improve productivity of a can manufacturing industry

Impact of Stakeholders on Lean Six Sigma Project Costs and Outcomes during Implementation in an Air-Conditioner Manufacturing Industry

Modern manufacturing operations always aim toward sustainable production through sustainable operations. Lean Six Sigma manufacturing is one of the leading models to increase operational efficiency and productivity and reduce product manufacturing costs. The lean Six Sigma problem-solving methodology DMAIC has been one of the several techniques organizations use to improve their productivity and the quality of their product and services. This paper aims to apply Lean Six Sigma and DMAIC to enhance production capacity and reduce per-unit cost. Furthermore, this research work has been carried out to analyze the impact of stakeholders on Lean Six Sigma projects. The research follows the DMAIC methodology to investigate and analyze the root cause of the problems and give possible solutions for eliminating or reducing the issues. Particularly, fishbone and 5-Whys techniques were used to determine whether the two key processes, AC Outdoor unit testing with the help of reusable power cords and the un-efficient use of expanding machine, had an impact on low productivity and high per-unit cost. The analysis indicated the importance of stakeholders in lean Six Sigma projects. It has been found that key stakeholders can affect the result of lean Six Sigma projects, e.g., in the power cord modification project, a total of USD 7738 has been lost, while in expanding machine modification project total of USD 1339 has been lost due to ignorance of key stakeholders in both projects. This paper provides practical guidance to lean Six Sigma project team leaders to develop and define the key stakeholders at the beginning of the project and clearly identify the stakeholders’ responsibilities. Furthermore, the project leader must analyze and identify internal and external stakeholders b/c stakeholders may be internal or external. This paper provides theoretical guidance to lean Six Sigma project team leaders since ignoring stakeholders could give a misleading picture in terms of project cost, savings, and duration of the project. The project leader must consider key stakeholders’ costs and future strategies before starting the project. Although some project managers and experts have conducted analyses of stakeholders’ impact on projects, lean Six Sigma literature lacks solid examples of stakeholders’ impact on LSS project results. This study tries to address this research gap by analyzing the impact of key stakeholders on LSS projects.

Six sigma application requirements to improve the administrative performance of the public authority for sports in the State of Kuwait

This study aimed to explore the extent to which the requirements for the implementation of the Six Sigma method are met at the Public Authority for Sports in Kuwait by focusing on the senior management’s understanding for its philosophy and requirements, satisfaction of beneficiaries, the nature of training methods provided for the staff and the effectiveness of communication systems. These points were also explored from the perspectives of beneficiaries. The sample of the study consisted of (30) officials from the Public Authority for Sport who were chosen using a random sampling and 400 beneficiaries who were chosen using a purposive sampling. To achieve the aim of the study, two questionnaires were administrated and analyzed statistically. Results revealed a gap between the senior management in the public authority for sport (officials) and its beneficiaries and a clear weakness in the communication methods which created a dilemma for implementing Six Sigma method. Findings also suggested the lack of transparency in sport governance which does not align with the requirement of Six Sigma. Furthermore, the application of Six Sigma method needs development of and adoption for a new administrative method that takes into considerations beneficiaries’ needs and desires. Therefore, the study proposed a model based on DMAIC methodology for implementing the Six-Sigma method as a way of improving the Public Authority for sport’s administrative performance.

Improving the Finishing Process of Food Packaging Products Using DMAIC Method

PT PP2 which is engaged in printing and packaging manufacturing has to provide good quality products and continue to make improvements to survive and win the competition. Currently, PT. PP2 produces a premium product which is a Food Packaging Product program from a company namely Target. Unfortunately, there were many defects found in the production area especially in the Finishing Process Section. Based on the historical data from August 2019, there were 184 pieces of defective products per shift. This study is conducted to reduce four main defects in the finishing process section of food packaging products which are Bending, Plastic Broken, Damaged Shrinkwrap, and PET Bumpy. The DMAIC methodology as a proven and well-known quality improvement method is selected for solving the problem escorting other methods or tools such as why-why analysis, brainstorming, Kaizen activities, and FMEA. The result of implementation shows that defects decreased by 9.05% (from 184 pieces to 21 pieces of defective products per shift) or from 10% down to 1.17%. With this achievement, PT PP2 can be meet the customer requirement and deliver the product within time. This study again also shows that DMAIC is one of the best choices in improving quality, especially in manufacturing industries.

PENERAPAN PRINSIP SIX SIGMA DALAM MEMBANGUN MANAJEMEN MUTU PENDIDIKAN ISLAM

AbstractThis article focuses on conducting a study on the application of six sigma in building quality management of Islamic education. This article examines the literature on six sigma which is usually applied to the business world and adapts it to the quality management of Islamic education. The authors use are applying the DMAIC methodology (define, measure, analyze, improve, control). The results of the discussion about six sigma there are two forms of application in education quality management. 1) implementation of six sigma in improving the quality of education. Elements that are directly related to the education process in schools are school supervisors, principals, and teachers. From these elements are able to apply six sigma in the process of improving the quality of education, able to overcome or reduce existing problems. 2) the application of six sigma in improving the organization in educational institutions. a) schools carry out designs, b) schools produce graduates who are able to master various cognitive fields, c) schools are able to design a good curriculum, d) schools are able to carry out the learning process in accordance with the curriculum, e) schools determine fair assessments according to the assessment instrument, f) schools have qualifications for competence and education personnel, g) are able to form RKS and RKAS.Keywords: six sigma; Quality management; Islamic education

PERBAIKAN MESIN UNTUK MENINGKATKAN PELAYANAN BENGKEL PELABUHAN PERIKANAN NUSANTARA KECAMATAN SUNGAILIAT KABUPATEN BANGKA

The service of Pelabuhan Perikanan Nusantara Sungailiat workshop to fishermen was disrupted due to reduced machine availability caused by the failure of lathes, hydraulic press, drills, and grinders. This project aims to repair machine damage, so machine availability increases and workshop services return to normal.. The implementation method is carried out with corrective maintenance procedures to identify and fix the cause of damage or failure in a failed or damaged system. To verify the types of problems affecting machine’s condition using the Six Sigma DMAIC (Define-Measure-Analyze-Improve) methodology and why-why analysis. The results indicate that lathes, hydraulic presses, drills, and grinders can function well. Even though the hydraulic press machine can perform to press the product, it has not returned to the factory standard. Overall the machines can be used to provide repair services for fisherman boat engine tools/components and fishing gear. It is necessary to build a preventive maintenance system and the performance parameters of these machines so that their condition is always maintained and damage does not recur.

Standardization of manufacturing times in the Company Industrias Inca S.A.S (AZZORTI), through the implementation of databases with times analyzed through MTM

This article is based on research and development of project Operation standarization through MTM developed in company Industrias Inca S.A. or Azzorti how is more known in 2022, the project aims time standarization. Time manufacturing standarization are the main base to make the launching development of the company and its accuracy is the main guideline for costs assertiveness, however, currently not all times are standarized, even among the same type of clothing. This project was implemented based on DMAIC methodology, first defining the problem, and comparing metrics, then observing and making comparative analysis of competition factors. an analysis and observation were made with different methods of the company and those were validated with MTM´s sequences. The methodology establishment to define each time operation through MTM is based on existent theories so far, combined with manufacturing formulas. Found deviation cost analysis and impact itself are presented, from which goals in the cost deviation indicators a main base with times based on movements MTM is proposed. This article shows how it’s possible to implement an standarized data base and based on theory without need to buy an specialized program, those one could be implemented from the presented scheme and it can be the main element of operational routes and costs of any company, medium or large. The cost impact becomes in the main reason to make the decision to implement it, this methodology could be implemented in large companies that already have a development process, or small and medium companies that will help to them to make an easier and organized process.

SIX-SIGMA GUIDELINES TO IMPROVE INVENTORY MANAGEMENT IN A BOTTLING COMPANY

Warehousing allows timely distribution of goods between suppliers, manufacturers, retailers, and end customers. Thus, its optimal performance is crucial for the global supply chain. While there are methodologies to accomplish its optimal performance, few practical cases are reported in the specialized literature. This work describes the implementation of Six-Sigma to improve the warehousing operations associated to inventory management in an international bottling company in Mexico. This was performed through the DMAIC methodology with the following qualitative and quantitative tools: 5WH1, Root Cause Analysis, Ishikawa Diagram, SIPOC, and the 5 Why’s. After a three-month implementation plan, the improved inventory policies reduced stockout/overstock risks, order rejection rates, warehouse saturation, loading/unloading maneuvers, unsuitable storing practices, and increased distribution fleet utilization. These improvements implicated expected annual savings of approximately $4.0M, which can be increased if other processes beyond warehousing such as route and location planning are considered. The implementation details contribute to the limited case studies literature that can support the application to solve warehousing problems in other industries.

Streamlining surgical trays for common pediatric urology Procedures: A quality improvement initiative

Procedures involving the external genitalia are the most common pediatric urologic operations. Our group identified excess instrumentation for these cases to be a potential cause of operating room (OR) inefficiency at our large, freestanding pediatric hospital. This quality improvement (QI) initiative aimed to streamline surgical instrumentation for the most-performed pediatric urologic procedures at our hospital. Six Sigma DMAIC methodology (Define, Measure, Analyze, Improve, Control) guided this multidisciplinary, iterative QI effort. A stakeholder team utilized data review, direct observations, and multiple in-person discussions to create a new "Groin-Penis Tray" (GPT) to replace a larger tray for the 90 most common pediatric urologic procedures. Suture preference cards and expectations about which sutures would be opened for each case were updated. The primary outcome was estimated yearly cost-avoidance due to reduced sterile processing. Additional outcomes included: instruments opened/case, % cases with complete trays, Mayo stand set-up time, and % cases with unused sutures. Balancing measures included: total median OR time and tray weights. Baseline and post-implementation measures were characterized and compared. A QI professional, 10 pediatric urologists, 2 pediatric urology fellows, and multiple OR and sterile processing staff members participated. The Summary Figurecompares baseline and post-implementation measurements. The number of instruments opened/case decreased from 146 to 65. Annual sterile reprocessing costs decreased by >$51,000. Median Mayo stand set-up time decreased from 7.3 to 3.5min (p<0.001). The number of cases with complete trays increased from 7/20 (35%) to 11/20 (55%, p=0.34). The new GPT is 2.7kg lighter than the prior tray. Median OR time remained stable (baseline: 91min; post-implementation: 102min, p=0.44). The number of cases with suture waste decreased from 78% to 0% immediately post-implementation but increased to 40% one year later. This systematic, iterative QI process spanned the course of ∼2 years, including planning, building, and updating new trays, then assessing longer-term success via the control phase. The new GPT is used for most pediatric urologic procedures at our hospital, and benefits include sterile reprocessing cost savings and ergonomics. Our team gained valuable experience related to assessing QI project scope, determining key stakeholders and roles, and strategies for sustainability that we will apply to future initiatives. Streamlining surgical trays for common pediatric urologic procedures at a large freestanding children's hospital using established QI methodology reduced OR cost by >$51,000/year and Mayo stand set-up times without compromising balancing measures.

Review Paper: Quality Improvement through Six Sigma using DMAIC Methodology in construction

Review Paper: Quality Improvement through Six Sigma using DMAIC Methodology in construction

Enhancing the Quality Improvement through Six Sigma Using DMAIC methodology in construction

Enhancing the Quality Improvement through Six Sigma Using DMAIC methodology in construction