Sigma Methodology Research Articles

OEE improvement through reducing start up duration using lean Six Sigma methodology in manufacturing

OEE improvement through reducing start up duration using lean Six Sigma methodology in manufacturing

Revolutionizing Crystal Guava Production through Six Sigma and Kaizen Insights

This study addresses the quality issues in crystal guava production at UD Bumiaji Sejahtera using the Six Sigma and Kaizen methodologies. By analyzing factors like non-uniform maturity, black spots, fruit rot, shape defects, and seed defects, this research aims to identify key areas for improvement. Results indicate that non-uniform maturity contributes significantly to defects, highlighting the need for improved pest control, efficient application methods, regular maintenance, material inspection, and enhanced standards for farmers and agricultural workers. These findings offer practical insights for enhancing crystal guava production quality and reducing defects at UD Bumiaji Sejahtera. Highlight: Six Sigma and Kaizen for Crystal Guava Quality Enhancement. Non-uniform Maturity Identified as Key Defect Contributor. Recommendations: Improved Pest Control, Application Methods, and Standards for Farmers. Keyword: Crystal Guava Production, Six Sigma, Kaizen, Quality Improvement, Defect Reduction

Research on the Construction of an Emergency Group Injury Classification Management Model based on the Six Sigma Methodology

Objective: This study aimed to investigate an effective management model for coping with critical incident group injuries. Methods: The study started and ended from January 2022 to December 2023, in which 68 patients with critical incident group injuries admitted from January 2022 to December 2022 were selected as the control group in the conventional management mode, and 76 patients with critical incident group injuries admitted in the hospital were selected as the study group in the classification management mode based on the Six Sigma method to compare the management effects of the two groups. The management effects of the two groups were compared. Results: The study group took less time to rescue than the control group, and the resuscitation success rate was higher than that of the control group (P < 0.05). Conclusion: The classification management model based on the Six Sigma method is effective and can be popularized and applied in medical institutions.

Improving value chain data lifecycle management utilising design for Lean Six Sigma methods

PurposeThis project aims to optimise a secondary agricultural company’s reporting and data lifecycle by providing self-help business intelligence at an optimal price point for all business users.Design/methodology/approachA design for Lean Six Sigma approach utilising the define, measure analyse, design and verify methodology was utilised to design a new reporting and data product lifecycle.FindingsThe study found that this approach allowed a very structured delivery of a complex program. The various tools used assisted greatly in delivering results while balancing the needs of the team.Practical implicationsThis study demonstrates how improving data analysis and enhanced intelligence reporting in agribusinesses enable better decision making and thus improves efficiencies so that the agribusiness can leverage the learnings.Social implicationsImproving data analysis increases efficiency and reduces agrifood food wastage thus improving sustainability and environmental impacts.Originality/valueThis paper proposes creating a standardised approach to deploying Six Sigma methodology to correct both the data provisioning lifecycle and the subsequent business intelligence reporting lifecycle. It is the first study to look at process optimisation across the agricultural industry’s entire data and business intelligence lifecycle.

Using the Lean and Green Six Sigma Method at PT. XYZ, this Painting Process aims to Reduce Tosou Butsu Alloy Wheel Defects

Aluminium wheels are a significant component of the automotive industry, but opinions about their quality are primarily based on how they look. As a result, finishing is crucial to the production process in the wheel industry. Efforts must be made to reduce the frequency of Tosou Butsu flaws in the painting process, which most frequently occur in the paint section, even though there are still a lot of errors in the wheel production process. Therefore, to lessen the chance of Tosou Butsu faults developing during the wheel finishing process, the Lean & Green Six Sigma technique is applied. Measure, Analyze, Improve, Control, and Define are the five stages of the Six Sigma methodology (DMAIC). Conversely, the Six Sigma level has grown from 3,417?, which was the level before the Sigma was repaired, to 3,750? in Sigma level 3 conditions, or level 4 conditions, with the potential for Tosou Butsu defects to occur at 12104 for a million production processes. Six Sigma is then applied to In this investigation, the painting procedure was able to lower the percentage of Tosou Butsu faults from 0.0276 to 0.0121. In order to optimize efficiency and focus on system mechanisms that align with standard operating procedures and human resource development, the Six Sigma process needs to be applied regularly and refined until the Sigma level reaches 6?.

Study on Lean Six Sigma methodology from the Indian context: an investigation of literature

PurposeIndia liberalized its economy in 1991, which resulted in intense global competition, quality-conscious and demanding customers. Additionally, significant technological advancements lead to enhancements in products and processes. These forced Indian organizations to adopt innovative business strategies in the past 30 years. Meanwhile, the Lean Six Sigma methodology has significantly grown with vast applicability during the past 30 years. Thus, the purpose of this study is to develop the learning on Lean Six Sigma methodology in the Indian context through investigation of literature.Design/methodology/approachA three-stage systematic literature review approach was adopted to investigate the literature during the present study. In total, 187 articles published in 62 journals/conference proceedings from 2005 to 2022 (18 years) were shortlisted. The first part of the article summarizes the significant milestones towards the quality journey in the Indian context, along with the evolution of the Lean Six Sigma methodology. The second part examines the shortlisted papers on Lean Six Sigma frameworks, their applicability in industrial sectors, performance metrics, outcomes realized, publication trends, authorship patterns and leading researchers from the Indian perspective.FindingsLean Six Sigma has emerged as a highly acclaimed and structured business improvement strategy worldwide. The Indian economy has seen remarkable growth in the past decade and is one of the fastest-growing economies in the 21st century. Lean Six Sigma implementation in India has significantly increased from 2014 onward. The study revealed that researchers have proposed several different frameworks for Lean Six Sigma implementation, the majority of which are conceptual. Furthermore, the balanced applicability of Lean Six Sigma in manufacturing and service sectors was observed with the highest implementation in the health-care sector. Additionally, the widely adopted tools, techniques along with performance metrics exploring case studies were reported along with a summary of eminent and leading researchers in the Indian context.Research limitations/implicationsThis study is confined to reviewed papers as per the research criteria with a significant focus on the Indian context and might have missed some papers due to the adopted papers selection strategy.Originality/valueThe present study is one of the initial attempts to investigate the literature published on Lean Six Sigma in the Indian context, including perspective on the Indian quality movement. Therefore, the present study will provide an understanding of Lean Six Sigma methodology in the Indian context to graduating students in engineering and management and entry-level executives. The analysis and findings on Lean Six Sigma frameworks, research approach, publications details, etc., will be helpful to potential research scholars and academia. Additionally, analysis of case studies on Lean Six Sigma implementation by Indian industries will assist the managers and professionals in decision making.

Application of Lean Six Sigma in Dermatology Practice

The Lean Six Sigma (LSS) methodology integrates two quality improvement techniques to enhance efficiency, reduce waste, and improve the quality of processes and products within an organization. While it has found application in various healthcare settings, to the best of our knowledge, there is currently no literature addressing its utilization in a community dermatology clinic. This study aimed to identify efficiency issues within a local dermatology clinic and implement targeted strategies to bolster collaboration, streamline processes, reduce wait times, augment patient volume, and enhance clinical outcomes and the quality of care. Five areas for improvement were identified: the building complex, front office, EMA system, medical assistants, and general improvements. The executed changes effectively standardized multiple processes, mitigated the potential for errors, and minimized task duration. These findings underscore the efficacy of LSS as a potent tool for enhancing efficiency and reducing waste. Efforts should be directed toward the incorporation of LSS techniques for quality improvement within healthcare systems, both internally and across interconnected entities.

Six Sigma Technique to Reduce Waiting Time: A Practical Application in Passport Affairs Directorate

This study investigates the impact of the Six Sigma methodology on improving waiting times in passport directorates. The Six Sigma methodology is crucial for enhancing efficiency and effectiveness in passport directorates, aiming to reduce waiting times and increase customer satisfaction by organizing services more effectively. The research was conducted in the Passport Affairs Department (Mansour Passports) from November 8, 2022, to April 19, 2023, with a sample size of 53 employees and citizens. The problem of this study is to shed light on the role played by the Six Sigma methodology in improving waiting time at the Passport Affairs Department. The study adopted the DMAIC methodology (Define, Measure, Analyze, Improve, and Control) and used statistical software (SPSS) to calculate Six Sigma levels for both citizens and employees. Access and service data analysis was conducted using Win QSB software, and arrival and service times were calculated for all stages (counter employees, accounts, and manager's computer). The most significant results indicate that the directorate operates at the first level of Sigma levels, while citizens are at the second level. There is a significant and inverse effect of Six Sigma principles on waiting. The total time a citizen waits from entering the passport office to receiving their passport is very long. Paper type: Research Paper

Six Sigma in preconstruction: case study on improving of reinforcement steel processing

Lean process improvements are crucial for enhancing production efficiency. In my research, I examine the application of the DMAIC methodology to develop the MEP facility within the framework of lean Six Sigma. Highlighting the challenges of precast concrete production, my study details how lean management aids in efficient process design and measurement. Introducing lean Six Sigma methodology involves standardizing processes and ensuring their effective development, contributing to the facility's efficiency

Six Sigma driven QC management in hepatitis C serology

The Westgard quality control (QC) rules are often applied in infectious diseases serology to validate the quality of results, but this requires a reasonable tradeoff between maximum sensitivity to errors and minimum false rejections. This article, in addition to illustrate the six sigma methodology in the QC management of the (anti-HCV Architect®) test, it discusses the main influencing factors on sigma value. Data from low positive and in-kit control materials spreading over 6 months and using four reagent kits, were used to calculate the precision of the test. The difference between the control material reactivity and the cut-off defined the error budget. Sigma values were >6, which indicates that the method produces four erroneous results per million tests. The application of the six sigma concept made it possible to argue the choice of the new QC strategy (use of 13S rule with one positive control) and to relax the existing QC rules. This work provides a framework for infectious diseases serology laboratories to evaluate tests performances against a quality requirement and design an optimal QC strategy.

Requirements Applying of Six Sigma Methodology to Reduce Productive Wastage at Yemeni Pharmaceutical Manufacturing Companies: A Field Study

The Study aimed to identify the impact of Requirements Applying of Six Sigma Methodology with its dimensions (Top Management commitment and support, Continuous Improvement, Human Resources, technology and information systems) on Reducing Productive Wastage, the level of Requirements applying it and the Reducing Productive Wastage at Yemeni Pharmaceutical Manufacturing Companies. To achieve the study objectives, the descriptive analytical method was used and the study population consisted of the workers in Yemeni Pharmaceutical Manufacturing Companies with a total number of (476) employees. The study questionnaire was distributed on stratified random sample with a total number of (195) employees. By analyzing the data using descriptive analysis methods and multiple regression analysis using the SPSS program, the findings revealed positive impact of Requirements Applying of Six Sigma methodology on the reduction of productive waste in Yemeni Pharmaceutical Manufacturing Companies, and also that there is a positive impact of the three Applying of Six Sigma Methodology dimensions: Continuous Improvement, information and technology systems and Human Resources on Reducing Productive Wastage, while there was no impact of the top Management commitment and support on Reducing Productive Wastage in Yemeni Pharmaceutical Manufacturing Companies, due to the variation in the workers awareness level of Requirements Applying of Six Sigma Methodology. The findings also showed that the level of Requirements applying of the six-sigma methodology at Yemeni Pharmaceutical Manufacturing Companies was high, and the level of Reducing Productive Wastage was high as well in Yemeni Pharmaceutical Manufacturing Companies.

Application of Six Sigma methodology in the analysis of variance: process shift versus inflation coefficient

Purpose The purpose of this article is to study the link between mean shift and inflation coefficient when the underlying null hypothesis is rejected in the analysis of variance (ANOVA) application after the preliminary test on the model specification.Design/methodology/approach A new approach is proposed to study the link between mean shift and inflation coefficient when the underlying null hypothesis is rejected in the ANOVA application. First, we determine this relationship from the general perspective of Six Sigma methodology under the normality assumption. Then, the approach is extended to a balanced two-stage nested design with a random effects model in which a preliminary test is used to fix the main test statistic.Findings The features of mean-shifted and inflated (but centred) processes with the same specification limits from the perspective of Six Sigma are studied. The shift and inflation coefficients are derived for the two-stage balanced ANOVA model. We obtained good predictions for the process shift, given the inflation coefficient, which has been demonstrated using numerical results and applied to case studies. It is understood that the proposed method may be used as a tool to obtain an efficient variance estimator under mean shift.Research limitations/implications In this work, as a new research approach, we studied the link between mean shift and inflation coefficients when the underlying null hypothesis is rejected in the ANOVA. Derivations for these coefficients are presented. The results when the null hypothesis is accepted are also studied. This needs the help of preliminary tests to decide on the model assumptions, and hence the researchers are expected to be familiar with the application of preliminary tests.Practical implications After studying the proposed approach with extensive numerical results, we have provided two practical examples that demonstrate the significance of the approach for real-time practitioners. The practitioners are expected to take additional care before deciding on the model assumptions by applying preliminary tests.Originality/value The proposed approach is original in the sense that there have been no similar approaches existing in the literature that combine Six Sigma and preliminary tests in ANOVA applications.

Sustainable water solutions:a Six Sigma approach to membrane-based filtration system design

Water contamination is a major problem nowadays which can not only be solved through technological innovations but also requires educational innovation. The contamination of water is caused by discharging harmful pollutants into the water. These harmful contaminants cause different diseases. The significance of water filtration has grown in recent years. The quality of water is affected majorly by residual waste, bacteria, and so on. Based upon these issues, the Six Sigma methodology is used in this research for the design of a portable filtration system. This methodology is based on five steps that align with the computational competencies involving abstraction, decomposition of problem, and algorithmic thinking. Initially, a questionnaire approach is used to identify the need for a portable water filter for potential users. The Quality Function Development (QFD) matrix is used to measure the user’s needs. Based on the user’s information, a decision matrix tool is being used in the Analyze stage. After this theoretical concept is generated, and selection is made among various options. The complete drawing was made in the design stage after several stages of concept generation and selection. Then a prototype is developed to conduct proof of concept testing. The hollow fiber membrane (HFM) that is being used is manufactured usually by melt spinning, dry spinning, and wet spinning. But usually, a wet spinning method is predominantly used for manufacturing hollow fiber membranes. Polymer liquid like polyvinyl chloride (PVC) is used for the manufacturing of membranes with other liquids in different ratios. The size of pores varies from 0.01 to 0.1 microns. The flux rate usually depends upon the volume, length, and size of the cartridge. Backwashing at regular intervals is done for the presentation of fooling due to the accumulation of solutes. This filtration system is also proficient in rejecting bacteria that are being found in water and soil. This is done by a coliform test that is being performed for bacteria. The porosity of the membrane is also affected by the concertation of polyvinyl chloride (PVC) as the concentration of polyethylene glycol increases the porosity of the membrane decreases. A Chemical Oxygen Demand test is also performed to check the presence of organic matter in water. After filtration, no organic matter was manifested in the water. Design for Six Sigma in a portable filtration system that uses membrane for filtration is a good start in looking for a new alternative concept. The implication of this research presents a multifaceted solution to water contamination issues, offering educational outreach programs, STEM education integration, community engagement, and innovative competitions as integral components for fostering awareness, sustainable practices, and creative solutions in the pursuit of clean water.

Leveraging Six Sigma for Enhanced Reliability in Heavy Equipment Operations

This study addresses the prevalent issue of mechanical failures in heavy equipment and dump trucks within a leading special steel production firm. Utilizing the Six Sigma methodology, the research conducted in August 2023 aimed to systematically design and implement corrective actions to improve maintenance processes. Preliminary results from the IRGA Department's interventions suggest a significant reduction in breakdown frequency and severity, indicating enhanced operational efficiency and reduced downtime. These findings highlight the potential of Six Sigma as an effective tool in optimizing industrial maintenance strategies, with implications for boosting productivity and sustainability in heavy industries globally. Highlights: Regular maintenance prevents costly damage. Six Sigma ensures systematic improvement. Vision: Leading in quality and environmental care. Keywords: Steel Bar Casting (billet), Flat Bar, Round Bar Production

Reducing the length of stay for patients stranded in the emergency department: A single-center prospective study of 18,631 patients in China.

The purpose of this study was to reduce the length of stay (LOS) for patients stranded in the emergency department (ED) of a Grade III A hospital in China, and to improve patient flow and increase bed capacity. We utilized a pre-/postintervention design and employed the Six Sigma methodology, which is based on the DMAIC cycle (define, measure, analyze, improve, and control), to evaluate and improve the existing process. Data from 18,631 patients who were stranded in the ED were collected and analyzed. The median LOS for stranded patients decreased from 17.21 (6.22, 27.36) hours to 13.45 (5.56, 25.85) hours (P < .05). Similarly, the median LOS for admitted patients decreased from 19.64 (7.77, 27.68) hours to 15.92 (6.19, 26.24) hours (P < .05). The median LOS for patients with an ED triage Level IV decreased from 16.15 (5.80, 26.62) hours to 12.59 (5.20, 24.97) hours (P < .05). In addition, the average hospitalization days of hospitalized patients decreased from 0.92 days to 0.82 days (P < .05). Furthermore, the bed utilization rate increased from 66.79% to 72.29% (P < .05). The number of bed turnovers in the ED resuscitation room increased from 20.30 to 21.96 (P < .05). We had effectively met our goal of minimizing ED patient LOS. Six Sigma method can effectively shorten patient LOS by measuring and analyzing the key factors affecting patient LOS, and by implementing measures such as strict implementation of emergency classification and triage system, establishment of multidisciplinary cooperative team, reasonable allocation of human resources, information management of bed resources, and improvement of performance appraisal scheme to improve and control the effectiveness of patient LOS.

UTILIZACIÓN DE LOS MODELOS DE ECUACIONES ESTRUCTURALES CON MÍNIMOS CUADRADOS PARCIALES PARA IDENTIFICAR LOS FACTORES CRÍTICOS DE ÉXITO EN LA IMPLEMENTACIÓN DE LA METODOLOGÍA 6 SIGMA

The Six Sigma Methodology (SSM) is a useful tool for the improvement of the quality of the companies, this methodology is constituted by a set of methods of: statistical analysis, collection and analysis of data from its suppliers, customers, and production of the company; analysis of production costs, and, in addition, it is considered as a systematic methodology for the design of new products.

QFD-based hybrid neutrosophic MCDM approach with Six Sigma evaluation for sustainable product design in Industry 4.0

PurposeThe concept of sustainable product design (SPD) is gaining significant attention in recent research. However, due to inherent uncertainties associated with new product development and incorporation of multiple qualitative and quantitative criteria; SPD is a complex and challenging task. The purpose of this paper is to introduce a novel approach by integrating quality function deployment (QFD), multi-criteria decision making (MCDM) technique and Six Sigma evaluation for facilitating SPD in the context of Industry 4.0.Design/methodology/approachThe customer requirements are evaluated through the neutrosophic-decision-making trial and evaluation laboratory-analytic network process (DEMATEL-ANP)-based approach followed by utilizing QFD matrix to estimate the weights of the engineering characteristics (EC). The Six Sigma method is then employed to evaluate the alternatives’ design based on the ECs’ values.FindingsThe effectiveness of the suggested approach is illustrated through an example. The result indicates that utilization of the neutrosophic MCDM technique with integration of Six Sigma methodology provides a simple, effective and computationally inexpensive method for SPD.Practical implicationsThe proposed approach is helpful in upstream evaluation of the product design with limited experimental/numerical data, maintaining a strong competitive position in the market and enhancing customer satisfaction.Originality/valueThis work provides a novel approach to objectively quantify performance of SPD under the paradigm of Industry 4.0 using the integration of QFD-based hybrid MCDM with Six Sigma method.

A Retrospective Study to Evaluate the Quality Assurance of Thyroid Profile In A Tertiary Care Clinical Biochemistry Laboratory

Background: The Six Sigma methodology has become a standard in quality assessment and management, widely adopted in various industries since the mid-1980s. This methodology is applicable wherever the outcome of a process needs measurement. One area where Sigma metrics find utility is in laboratory services, particularly in evaluating the quality assurance of biochemical parameters. Aims: This study aimed to measure and analyze the sigma metrics of thyroid hormones T3, T4, and TSH within the framework of NABL accreditation (National Accreditation Board for Testing and Calibration Laboratories). Materials &amp; Methods: The study was designed as a retrospective observational study, utilizing quality control data from the Clinical Biochemistry section spanning from January 2021 to December 2021 retrieved from laboratory records. The data considered included Bio-Rad Lyphochek Immunoassay Internal Quality Control (IQC) Control and Bio-Rad External Quality Assurance Scheme (EQAS) Immunoassay monthly program data. Calculations for Coefficient of variation (CV %), Bias %, and Total Error allowable (TEa) were made to derive the sigma metric. The formula used for sigma calculation was Sigma Σ(σ) = (TEa% - Bias%) / CV%, while the Quality Goal Index (QGI) ratio was determined using the formula QGI = Bias / 1.5CV. Results: The results categorized the assay performance based on sigma levels: &gt;6 denoted world-class performance, 5-6 indicated excellence, 4-5 represented good performance, 3-4 was deemed acceptable, and 2-3 signified poor performance. All analytes demonstrated sigma levels below 6 (2.61-5.85) varying from poor to excellent and the QGI was below 0.8, indicating a need to enhance the precision of assays. Conclusion: The Six Sigma metric analysis serves as a benchmark tool that can aid laboratories in enhancing assay performance, formulating protocols for Internal Quality Control (IQC), and evaluating existing laboratory procedures. Keywords Six sigma, Quality Goal Index, Internal Quality Control

The application of operation research in the quality management engineering

The integration of Operations Research (OR) principles into Quality Management Engineering constitutes a powerful strategy for enhancing product and service quality throughout the entire lifecycle. This synergistic relationship unfolds within the context of OR, a discipline rooted in mathematical models, analytical methods, and decision-making tools, originally developed during World War II. Quality Management Engineering, built upon principles like Total Quality Management (TQM) and Six Sigma methodologies, systematically combines engineering principles with quality management techniques to ensure consistent high-quality outcomes. This interdisciplinary approach proves particularly critical in industries emphasizing precision, reliability, and efficiency. The application of OR in Quality Management Engineering encompasses diverse facets, including process optimization, supply chain management, quality control, root cause analysis, resource allocation, and risk management. This integration leverages mathematical modelling, statistical analysis, and optimization techniques to systematically improve and sustain product and process quality. Emphasizing continuous improvement, the collaboration integrates Lean principles, waste reduction strategies, and a commitment to ongoing assessment. The partnership between OR and Quality Management Engineering remains adaptable to changing business landscapes, addressing human factors, environmental considerations, and the era of data-driven decision-making. This abstract highlights the evolution of OR and its contribution to creating a structured, data-driven, and analytical approach to decision-making in quality management. Ultimately, this integration shapes efficient, resilient, and quality-focused organizations, positioning them for success and competitiveness in dynamic industries.

Enhancing performance measurement of public procurement processes through the application of procurement delay index

Considering procurement process performance assessment, measurement systems such as balance scorecard and capability maturity models are used to assess procurement performance to give a reasonable indication of actual performance. These tools are ideal for practical applications that depend on other performance criteria but are short of comparing planned to actual timelines set for procurement processes. This fosters persistent delays in public procurement. Six Sigma implementation benefits including addressing process delays have fostered its implementation for service improvements. Unfortunately, Six Sigma implementation in public procurement is very rare largely due to its expensive nature. The objective of this study is to develop a Procurement Delay Index (PDindex): a performance measure in the context of a Six Sigma methodology that provides a specific value to describe the delays in the procurement process. To enhance uniformity in performance measurement of process timeliness, a rating scale for determining the timeliness of the procurement process is proposed. A practical demonstration of the application of PDindex for use by procurement professionals is also presented. PDindex serves as a standard by which to determine procurement processes’ timeliness and is less expensive to implement. A PDindex of 3σ has been recommended as the acceptable limit for procurement process delays.