Sigma DMAIC Methodology Research Articles

A Prospective Interventional Study on the Application of Lean Six Sigma DMAIC Methodology on Assessing and Improving Antimicrobial Stewardship in a Tertiary Trauma Care Hospital, Coimbatore, India

A Prospective Interventional Study on the Application of Lean Six Sigma DMAIC Methodology on Assessing and Improving Antimicrobial Stewardship in a Tertiary Trauma Care Hospital, Coimbatore, India

Enhancing Paper Cup Manufacturing Quality Using Six Sigma's DMAIC Methodology

Enhancing Paper Cup Manufacturing Quality Using Six Sigma's DMAIC Methodology

Powder Detergent Packaging Line Improvement by Lean Six Sigma DMAIC Methodology

This investigation was a case of study in the powder detergent packaging line and aimed to reduce all those wastes that do not add value to the product, increasing the cost of production. Reducing or eliminating waste within the manufacturing industry becomes necessary for sustainable businesses over time and keeps generating development. To achieve it, the Lean Six Sigma DMAIC methodology was implemented in a detergent powder packaging line, to identify the problems that afflicted and made production more expensive. By using quality tools (such as Pareto and Ishikawa diagrams, 5S application, Poka-Yokes, SMED, training personnel, and standardizing processes) it was possible to reduce unproductive times. Energy consumption was reduced by up to 20 %, also efficiency and machine availability increased by 10.98 % and 7.32 %, respectively. The general performance of the line increased by 15.16 %, which translates into significant monthly savings of USD 71 442.05. By applying these improvement techniques, the most significant efficiency was registered in 1 kg packages, going from 47 % to 89 %, approximately. To maintain this productivity and even to perfect it, it is necessary to hire specialized personnel who know the production processes and industrial operations.

USE OF CONTROL GRAPHICS TO IMPROVE THE ANTHRACITE CALCINATION PROCESS IN AN ELECTRIC FURNACE

In the present work, the study of the application of control charts was carried out in the improvement of an anthracite calcination process in an electric oven for the manufacture of electrode paste (Soderberg). As a support for the control charts, the Standardization tools, Cause and Effect Diagram and the Six Sigma methodology were used to identify problems and proposals of improvement for it. Additionally, the anthracite calcination process was also presented, which when done correctly, with material within the proposed resistivity range, guarantees the final quality of the product produced at the pulp mill. The results of this work show that with the use of the Control Graph together with the Six Sigma DMAIC Methodology and the Cause and Effect Diagram, it was possible to reduce the amount of material outside the range of value specification from 70% to 14%, an 56% reduction, which represents an average decrease of 179.2 tons of material out of specification per month, generating a drop in the amount of material to be reprocessed, which translates into savings for the company and the ability to supply material for the manufacture of electrode paste.

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

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.

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

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.

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.

Lean Implementation Framework: A Case of Performance Improvement of Casting Process

Globalization breeds increasing competition. In today&#x2019;s dynamic climate, lean thinking has been found a promising business continuous improvement strategy for improving quality while reducing product cost and delivery time. However, its implementation has dynamic nature of challenges that varies from industry to industry and country to country, necessitating a specific framework by taking all stakeholders onboard. This study aims to propose a lean implementation framework to reduce defects and waste to improve the performance of the metal casting industry. The structure of the framework has been divided into three phases namely the lean conception phase, lean implementation phase, and lean sustainability phase. The proposed framework integrates the six sigma DMAIC methodology with lean tools and techniques to reduce defects and achieve performance improvement. A solid cast software has been used as a computer-assisted casting simulation tool to perform the analysis of defects within the casting. Further, the proposed framework is demonstrated and validated by employing a real-time case study that was manufactured using the sand casting process. The obtained results show remarkable improvements in poured metal weight (33.3%), mold weight including gating system (40%), casting yield (24.56%, rejection rate (90%), and financial saving (24.63%). As a result of analysis of percentage improvements data, the proposed framework can provide the practitioners with a standard roadmap and motivate the casting industries to implement lean for performance improvement through organizational change. Through the effective application of the lean implementation framework, quality enhancement has been demonstrated.

SIX SIGMA IN PLASTIC INJECTION MOLDING: REUSE DEFECTIVE PARTS IN NEW ARTICLE PRODUCTION AS RAW MATERIAL INPUT OR NOT?

In production plants, re-processing of defective products and re-incorporating them into production as raw materials provides the advantages of reducing scrap and efficient use of material. However, using recycled defective plastic parts as raw materials in the production of new parts in plastic injection processes can create aesthetic problems for the final product. On the other hand, the aesthetic dimension of quality that fulfills customer expectations provides competitive advantage. Considering this, in this study, the root cause of the aesthetic problem that occurs as discoloration of a particular component manufactured in a plastic injection facility operating in the white goods industry was revealed and improvement was made. Six Sigma DMAIC methodology was applied to reduce high scrap rates caused by discoloration errors, and it was determined that the error was caused by reusing scrap plastic parts as raw materials in the production of new articles. With the elimination of this cause, the process capability was improved, the 3 sigma process capability was increased to the level of 4.7 sigma and the aesthetic appearance of the product was improved. This study has shown that the reutilization of defective plastic parts as raw material input in new article production is not a viable approach for particular products such as white goods products.

Automation of Predictive Maintenance Using Internet of Things (IoT) Technology at University-Based O&amp;M Project

Predictive Maintenance can be defined as a type of advanced maintenance that detects the onset of system degradation allowing causal stressors to be eliminated or controlled prior to any significant deterioration in component physical state. Thru Internet of Things (IoT) Technology, automation, and implementation of Predictive Maintenance are possible. The purpose of this study is to propose the implementation of Predictive Maintenance using IpT Technology at University-based Operation &amp; Maintenance Project that aims to transform the current Key Performance Indicator (KPI) of PM to CM Ratio from 80:20 to 90:10. Six Sigma DMAIC Methodology and Data-Driven Predictive Maintenance Planning Framework were utilized as the methodology of this research. Research’s results show that KPI, 90:10 (PM to CM Ratio) is achievable and maintenance cost can significantly reduce from 25% to 30%. Other valuable benefits are return of investment (10X), elimination of breakdown (70 - 75%), reduction in downtime (35% - 45%) and increase of production (20% - 25%). The proposed concept can be utilized in other industries to achieve high customer satisfaction percentages, sustainable operations, fault prediction, and online monitoring using PC or mobile applications.

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

Quality Improvement of Recycled Aggregate Concrete using Six Sigma DMAIC Methodology

Recycled aggregates (RA) are obtained from construction and demolished waste, laboratory crushed concrete and concrete waste at RMC plants. The concrete made from recycled aggregate is known as recycled aggregate concrete. The use of recycled aggregate is very beneficial to the environment in civil works. Its usage also helps in financial saving as the cost of transportation and production energy cost of natural coarse aggregate (NCA) is reduced. In India, the recycled aggregate application in lower grade concrete work is observed. However, the effect of recycled aggregate on the strength and durability of concrete restricts its use in higher-grade work. This paper presents a series of tests carried out on recycled coarse aggregate (RCA) and recycled coarse aggregate concrete (RCAC) and test results are compared with the NCA and parent concrete made from NCA. Tests were carried out as per IS code and concrete was prepared using a two-stage mixing approach in the concrete mix design. M30 concrete mix of four RCAC samples was tested at 28 days of curing and in comparison with parent concrete, it is found that on an average compressive strength is decreased by 12.89% at 28 days curing. Adhered mortar increases the porosity of the recycled aggregate and forms a weak zone between aggregate surface and mortar. In addition, test results showed the defects in recycled aggregate and helped to identify the area where concentration is necessary to improve the quality of recycled aggregate using six sigma DMAIC methodology. Total of 12 defects were found in the process and raw material. Statistical analysis was used to evaluate the performance of all the mix made with RCA.

Rectification of the improper mating of the rack and valve assembly using Six Sigma methodology at a steering manufacturing & assembly plant.

Precision automobile components and the automobile assembly systems are found to be the building element of any automobile, thus it is evident for the stakeholders to take utmost care and ensure that the most superior quality is delivered to the market. The minus cost principle says that when the quality is assured the time taken for the production is more which results in low volumes and where the volume is concerned the quality is compromised. Thus, focusing on one parameter results in the disturbance of the other. Hence, it should be balanced in such a way that the quality achieved is superior and with high volumes. While concentrating on the two parameters the parameter which is often neglected is the cost and it is found to be one of the most significant parameters for which the stakeholders have to focus upon. The following study illustrates how the quality factor was accounting for the heavy loss in a steering manufacturing company and how was the problem addressed with the most optimized solution thus eliminating the cost of poor quality. During the assembly of the steering system, three major components; the rack gear, the pinion gear and the housing are clustered and allowed to fit perfectly according to the design specification. Thus the method adopted to achieve the results was Six Sigma DMAIC Methodology. The DMAIC is an acronym for the Define Measure Analyze Improve and Control which is widely used in industries to address the problems when the problem is not easily identifiable.

Six Sigma-DMAIC and food waste hierarchy-based framework for reducing food waste in University canteens in Ethiopia

The aim of this paper is to propose a Six Sigma-DMAIC and food waste hierarchy-based framework that can be successfully implemented by Ethiopian University canteen managers to reduce food waste in a sustainable way. The importance of this research is twofold. First, the Six Sigma-DMAIC methodology is used to evaluate and improve the process to prevent food surplus and waste in the canteen. Second, other waste hierarchy options will be used to mitigate food waste problem in a sustainable way. This has a positive social, environmental, and economic implications.

Lean Six Sigma for Quality and Performance Improvement of POH Process of Wagon Wheel CTRB

Due to high competition in present world, every end user of a product demand their products to be delivered to them on time with good quality. Hence it is an objective of every industry to satisfy their customer requirements. In the long run, this can be achieved by continuous and constant process improvements. Lean Six Sigma is an overall quality improvement approach combining and capitalizing the strengths of Six Sigma and Lean Management improvement programs. In CTRB periodic overhaul, several process steps and workplaces are required for the job, the movement of inventory between the workplaces can be very time consuming unless it is suitably planned. The major areas that need great attention in this system are WIP (work in process), Takt time and process variability. In this study, focus is on the application of lean tools and techniques with their principles coupled with six sigma DMAIC methodology. The objective of this study is to identify the best possible tools and techniques to tackle premature failure of CTRBs whilst in service due to early presence of defects which are closely associated to the POH process. It also discusses the methodology generally adopted, tools and techniques used and benefits obtained. By mapping current state of the POH process and takt time, future state improvement can be done in order to reduce cycle time using Lean tools such as Poke-Yoke, Jidoka, 5S, SMED

Reduction in Call handling Time in Transportation service industry using Lean Six Sigma DMAIC methodology

The paper reviews the use of DMAIC six sigma methodology in a selected transportation cab service industry to improve customer satisfaction levels. The DMAIC comprises of five phases define, measure, analyse, improve and control. Various tools were used in the five phases starting with the voice of customer (VOC) matrix and project charter. Cause and effect diagram was used to find out the potential factors behind the high waiting time. Brainstorming sessions were also conducted to get a better sense of the high call handling time and suggestions were put forth to improve them. SMED analysis was also done to gauge the different changeover elements in the company. The average queue length for the 1st shift came down to 3.6 from 4.433 resulting in an estimated annual profit of $29250 annually.

Reduction in call handling time in transportation service industry using lean Six Sigma DMAIC methodology

Reduction in call handling time in transportation service industry using lean Six Sigma DMAIC methodology