Purpose
The purpose of this paper is to study the anodising process of a portable amplifier production process to identify and eliminate the sources of variations, in order to improve the process productivity.
Design/methodology/approach
The study employs the define-measure-analyse-improve-control (DMAIC) Six Sigma methodology. Within the DMAIC framework various tools of quality management such as SIPOC analysis, cause and effect diagram, current reality tree, etc., are used in different stages.
Findings
High rejection rate was found to be the main problem leading to lower productivity of the process. Four types of defects were identified as main cause of rejections in the baseline process. Pareto analysis resulted in detection of the top defects, which were then analysed in details to find the root cause of the problem. Further study resulted in finding improvement measures that were discussed with the management before implementation. The process is sampled again to check the improvements, and control measures were established.
Practical implications
The study provides a framework for implementation of DMAIC Six Sigma methodology for a manufacturing firm. The results presented are based on the data collected from the shop floor. Results and findings of the study were implemented for quality improvement of the process.
Originality/value
The study is based on an original research conducted with the objective of quality improvement in the anodising process of the production process. Besides presenting an approach to DMAIC Six Sigma methodology, an application of the current reality tree tool for root cause analysis is presented, a tool used limitedly in the Six Sigma studies. The tool finds its uniqueness in its ability to address problems relating multiple factors than isolated factors.
Here, stochastic analysis of a repairable system of three units has been carried out by taking one unit in operation (called main unit) and two identical units (called duplicate units) in cold standby. The switch device is used to convert the standby units into operative mode. A single server is hired to handle repair activities of the units who visits the system instantly whenever needed. The repair done by the server is perfect and thus the repaired unit follows the same lifetime distribution as the original. The constant failure rates are considered for both main and the duplicate units while their repair time distributions are taken as arbitrary. Some important reliability measures including mean sojourn times (MST), transition probabilities (TP), mean time to system failure (MTSF), availability, expected number of repairs for both kinds of units separately, expected number of visits by the server and busy period analysis of the server due to repair are determined using semi-Markov process (SMP) and regenerative point technique (RPT). The arbitrary values of the parameters are considered to examine the behaviour of some significant reliability measures through graphs. The possible application of the system model can be visualized in a power supply system of a house where a set of solar panels are kept in spare for their simultaneously working when main power supply is discontinued.
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