Application of six sigma methodology to reduce defects of a grinding process

Abstract

Six Sigma is a data-driven leadership approach using specific tools and methodologies that lead to fact-based decision making. This paper deals with the application of the Six Sigma methodology in reducing defects in a fine grinding process of an automotive company in India. The DMAIC (Define–Measure–Analyse–Improve–Control) approach has been followed here to solve the underlying problem of reducing process variation and improving the process yield. This paper explores how a manufacturing process can use a systematic methodology to move towards world-class quality level. The application of the Six Sigma methodology resulted in reduction of defects in the fine grinding process from 16.6 to 1.19%. The DMAIC methodology has had a significant financial impact on the profitability of the company in terms of reduction in scrap cost, man-hour saving on rework and increased output. A saving of approximately US$2.4 million per annum was reported from this project

A REVIEW OF SIX SIGMA IMPLEMENTATION IN INDIAN SMES – TOOLS & TECHNIQUES USED AND BENEFITS DRAWN

“…Six Sig ma is a business-driven, mu lti-faceted approach for reducing the defects and improving the process capability [41]. Six Sig ma is a well-structured methodology that focuses on reducing variation, quantifying non -conformance and make products, process and services defect-free [17]. Six Sig ma is a data-driven process improvement methodology used to make the process stable, outputs predictable and improve process capability.…”

Assessing the Success of Six Sigma: An Empirical Study

“…In spite, much of the literatures on six sigma are available only on its definition [4], needs [5], deployment [6], hurdles [7], project selection [8][9][10], critical success factors [11], framework [12- Issue ISBN: 978-81-930411-4-7 13] and organizational infrastructure required for implementation [14]. But only a few studies are reported regarding real life six sigma implementation [15][16][17][18][19][20].…”

A Six Sigma and DMAIC application for the reduction of defects in a rubber gloves manufacturing process

“…This stage aims at defining the project's scope and boundary, identifying the voice of the customer (i.e. customer requirements) and goals of the project (Gijo et al, 2011). However, before defining these elements within the project, the Six Sigma team has to be set up.…”

“… Define -this stage within the DMAIC process involves defining the team's role; project scope and boundary; customer requirements and expectations; and the goals of selected projects (Gijo et al, 2011).  Measure -this stage includes selecting the measurement factors to be improved (Omachonu and Ross, 2004) and providing a structure to evaluate current performance as well as assessing, comparing and monitoring subsequent improvements and their capability (Stamatis, 2004).…”