A case study: to reduce process variability of valve seat depth in cylinder head using Six Sigma methodology

Parsana, Tejaskumar S.; Desai, Darshak A.

doi:10.1504/ijpqm.2016.075250

Cited by 6 publications

(3 citation statements)

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“…Reducing annual rejection rate to more than 50 percent for cylinder head at a small- and medium-scale machining unit and achieving aggregate savings of about INR 19 million per annum (Parsana and Desai, 2016).…”

Section: Literature Reviewmentioning

confidence: 99%

Reducing failure rate at high voltage (HV) testing of insulator using Six Sigma methodology

Desai¹,

Shaikh²

2018

IJPPM

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Purpose This paper, a case study, aims to illustrate the application of Six Sigma in a small-scale ceramic manufacturing industry. The purpose of this paper is to demonstrate the empirical application of DMAIC methodology to reduce failure rate at high voltage (HV) testing of one of the most critical products, insulator. Design/methodology/approach The case study is based on primary data collected from a real-life situation prevailing in the industry. The case study methodology adopted here is at one small-scale unit wherein the authors have applied DMAIC methodology and observed and recorded the improvement results, especially, reduction in failure rate at HV testing of insulator and, thus, increase in Sigma level. Findings The results found after implementation of the solutions are very significant. The rejection percentage has been reduced from 0.5 to 0.1 percent and consequently the Sigma level has been improved from 4.4 to 5.0. Research limitations/implications This success story can be a guiding roadmap for other such industries to successfully implement Six Sigma to improve quality, productivity and profitability. Practical implications This case study will serve as one of the resource bases for the industries which have till not implemented Six Sigma and benefited from the same. Social implications Improved quality and productivity leads to better economy. This case will help industries to serve the society with better economy with improved quality and productivity. Originality/value Though ceramic industries in India are having enormous potential for growth, majority of them, especially, small and medium industries are either not aware of or not implementing Six Sigma to reap its multidimensional benefits of improving quality, productivity and profitability. This study highlights the benefits reaped by small-scale ceramic manufacturing industry opening up the avenues for its application at other such organizations.

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Section: Literature Reviewmentioning

confidence: 99%

Reducing failure rate at high voltage (HV) testing of insulator using Six Sigma methodology

Desai¹,

Shaikh²

2018

IJPPM

Self Cite

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“…Apart from above, few more successful implementations of Six Sigma in Indian industries are reported on the problem of rejection of welding electrodes due to variations in diameter of the manufactured units by Zaman et al (2013), on the flywheel casting process in foundry to minimize the defects in the process by Kumaravadivel and Natarajan (2013), in a manufacturing enterprise by identifying the root causes of failure for a welding defect resulting in quality and productivity improvement by Shashank et al (2013), at large food processing industries to address the problem of variations in the weight of milk powder pouch leading to the financial savings to the tune of INR 8,00,000 per annum by Desai et al (2015), on reducing annual rejection rate of the cylinder head at a small- and medium-scale machining unit and thus achieving aggregate savings of about INR 19 million per annum by Parsana and Desai (2016) and on reducing the external non-conformity from third-party inspection agency for a small-scale export-oriented unit industry and thus achieving savings of INR 81.70 lacs per annum by Prajapati and Desai (2016).…”

Section: Literature Reviewmentioning

confidence: 99%

Competitive advantage through Six Sigma at plastic injection molded parts manufacturing unit

Desai¹,

Prajapati

2017

IJLSS

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Purpose The purpose of this paper is to illustrate the successful application of Six Sigma at a small and medium scale plastic parts manufacturing unit. Overall operational excellence is one of the foundations of global competiveness. Indian industries are also keeping up with achieving and maintaining operational excellence through different improvement tools and methodologies. Plastic parts manufacturing industries in India are also on the move to increase their overall quality, productivity and profitability. However, it appears from the available literature that application of Six Sigma, one of the most effective breakthrough improvement strategies having direct impact on bottom line of the organization, is not being explored to its full potential, especially at plastic parts manufacturing industries in India. This study was thus undertaken at plastic products manufacturing plant to introduce Six Sigma to them by applying the same to their chronic problems and drawing improvements in quality, productivity and profitability. Design/methodology/approach This paper illustrates the real-life case study of improving quality and productivity of injection molding process by phase wiz application of define, measure, analyze, improve and control, the process improvement methodology of Six Sigma. Findings The critical defects, such as short molding, contamination, injection point and flash are reduced from the process leading to annual savings of INR 10.80 lacs. This is a considerable amount for a small concern in question. Research limitations/implications Because this was the pilot project and the firm was of small and medium size, data collection was the major issue, which consequently took considerable time and efforts at define and measure phases. Injection molding is a very salient process for plastic products manufacturing. Almost one-third of plastic products are made by this process. Thus, improving quality of products made out of injection molding process is of paramount importance. The paper is an attempt to exhibit how a small-scale plastic injection molded parts manufacturing unit can put fruitful efforts to achieve competitive advantage through Six Sigma. Originality/value From the review of literature, it appears that application of Six Sigma among plastic parts manufacturing units, especially small and medium, is very rare, not in India but across the globe. This case study has opened up the direction to small- and medium-scale plastic parts manufacturing units to implement Six Sigma and to move a step forward toward achieving competitive advantage.

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“…From the point of view of improving the processes, to authors as Montgomery (2009), the improvement of the quality is the reduction of the variability in the processes and products. This definition implies that if the variability of the important characteristics of a product, process or service decreases, the quality of the product, process or service increases (Tejaskumar and Darshak, 2016;Sukrut and Mohammed, 2017). Therefore, increasing the competitiveness of a company is closely related to a continuous improvement of the quality in all its processes (Sasadhar and Indrajit, 2018;Selvam et al, 2018).…”

Section: Introductionmentioning

confidence: 99%

Optimisation algorithms for improvement of a multihead weighing process

Rojano

Diaz

2019

IJPQM

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Mathematical optimisation is widely used to find the optimal value for an objective function, subject to constraints that try to simulate reality, and is fundamental to improving industrial processes. In this paper, we compare different optimisation approaches to solve the packaging problem in multihead weighing machines. In this problem, each package is made up from the loads in a subset of the multihead weigher's hoppers. The total weight of the packed product must be as close to a specified target weight as possible. We designed and evaluated a set of algorithms for this problem, considering both single-objective and bi-objective optimisation criteria. A new criterion for creating the packages is considered, and a different way of filling of the hoppers is studied with the aim of reducing process variability. Numerical experiments considering both a set of real data and the most important process performance parameters show the usefulness of our study.

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A case study: to reduce process variability of valve seat depth in cylinder head using Six Sigma methodology

Cited by 6 publications

References 0 publications

Reducing failure rate at high voltage (HV) testing of insulator using Six Sigma methodology

Reducing failure rate at high voltage (HV) testing of insulator using Six Sigma methodology

Competitive advantage through Six Sigma at plastic injection molded parts manufacturing unit

Optimisation algorithms for improvement of a multihead weighing process

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