Application of Six Sigma DMAIC methodology to reduce the defects in a telecommunication cabinet door manufacturing process

Quality improvement of magnetron in Company T based on Six Sigma

Purpose

The purpose of this study is to improve the magnetron quality in Company T by identifying the nonconforming defect, adjusting the factors affecting the leakage of the magnetron tube core, and determining the optimal parameter values of these factors.

Design/methodology/approach

A case study method is used to present the quality improvement of magnetron tube core. The define, measure, analyze, improve, and control framework is applied in the case study as well as several Six Sigma tools.

Findings

The results show that Ag–W thickness, Ag–W installation state and furnace entry interval are significant factors on the leakage of magnetron tube core, and the optimum settings for these factors are 0.055 mm, offset by 1 mm from the outer edge and 5 cm, respectively.

Research limitations/implications

The main limitation of this study is that it was carried out on a small number of production processes. The authors would like to analyze more case studies on the improvements of after-sales quality and supplier quality.

Practical implications

This research could be used in magnetron manufacturing process as a tool for managers and engineers to improve product quality, which can also be extended to similar manufacturing systems.

Originality/value

In this case study, the Six Sigma approach has been applied for the first time to solve magnetron manufacturing problems by improving the quality of magnetron production process. It can help the quality engineers be more familiar with the deployment of Six Sigma and effective tools.

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.

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

Purpose

Coronavirus disease 2019 is one of the novel diseases formed by a dreadful virus called Severe Acute Respiratory Syndrome Coronavirus 2. Various countries are affected by this viral disease, and many countries declare a lockdown with several rules and conditions. To prevent this rapid viral transmission, various researchers have introduced different mobile applications. This paper aims to study issues like viral transmission, mortality rates, vaccination rates, etc. and also provides suitable solutions based on the statistical analysis with the assistance of the Six-Sigma Define-Measure-Analyse-Improve-Control (DMAIC) concept.

Design/methodology/approach

Statistical analysis is done for different countries, and the required solutions are provided by using the DMAIC procedure. This application has the ability to represent the current risk status of the user and notify them to secure themselves.

Findings

The proposed work suggests the Aarogya Setu application to prevent large viral transmission by affording many preventive measures. This application also issues the current risk status of each individual user. Hence, it gives improved results in avoiding high viral transmission.

Originality/value

The proposed six-sigma DMAIC concept also affords the control measures to prevent viral transmission. Hence, the suggested application has the highest chance of avoiding the rapid viral transmission.

Application of Six Sigma methodology in an Indian chemical company

Purpose

The aim of this paper is to deploy Six Sigma (SS) methodology for addressing the customer complaints pertaining to Chemical-X in an Indian chemical company.

Design/methodology/approach

The study followed a structured Define, Measure, Analyze, Improve, Control (DMAIC) approach to address the customer complaints. The complaints have been classified into different categories along with a project charter in the define phase. In the measure phase, measurement system analysis (MSA) and supplier, input, process, output and control (SIPOC) have been applied. In the analyze and improve phase, why–why analysis, process capability study, how–how analysis, Gage repeatability and reproducibility and Taguchi design have been applied to optimize the manufacturing process parameters for Chemical-X. Lastly, in the control phase, validation of 20 batches has been piloted to validate the optimized parameters.

Findings

The findings of this study highlight the optimization and prioritization of the process parameters. It shows that humidity has the least impact on the manufacturing of Chemical-X, whereas shift type has the maximum impact. The experimental output indicates that the 1st Shift, the holding time after grinding should be twenty-four hours, and the temperature after grinding should be 40 °C to reduce the customer complaints concerning lumps formation in Chemical-X.

Research limitations/implications

The study is performed for a single product (Chemical-X). It has focused only from the manufacturing process view and not from the transportation, suppliers and downstream supply chain view.

Originality/value

A systematic and data-driven approach of the SS methodology ensured that the customer complaints due to lumps formation reduced from 5% (approx.) to 1% (approx.) which resulted in the cost saving of INR 4 million (approx.) annually.