Application of Six Sigma Tools in the Production of Welded Chassis Frames

Bucko, Michal; Schindlerová, Vladimíra; Hlavatý, Ivo

doi:10.17973/mmsj.2020_12_2020056

Cited by 5 publications

(7 citation statements)

References 5 publications

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“…The study resulted in improved sigma level, decreased parts per millions (ppm) levels and hence improved capability indices. One more study by Bucko et al (2020) applied LSS methodology in the production process of welded chassis frames in Czech Republic. The study resulted in improving performance and quality, reducing the number of defects occurring and reducing the cost of poor quality in production, both now and in the future.…”

Section: Previous Studiesmentioning

confidence: 99%

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A case study on implementing Lean Six Sigma: DMAIC methodology in aluminum profiles extrusion process

Araman¹,

Saleh

2022

TQM

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PurposeThis paper aims to investigate the sources of variation in aluminum profiles hot extrusion process for the purpose of process capability improvement at National Aluminum and Profiles Company (NAPCO) in Palestine. The critical-to-quality characteristics (CTQ) have been determined as base variables to measure the process capability.Design/methodology/approachThe DMAIC (Define, Measure, Analyze, Improve, and Control) Lean Six Sigma (LSS) approach has been adopted to conduct this study. More specifically, historical data analysis and PARETO charts have been employed. The defects' root causes have been determined using the cause-and-effect diagram and decision matrix. A course of suggested actions has been established to help in improving extrusion process capability. Minitab-18 software was used for conducting inferential statistical analysis. A case study considering a geometry CTQ of D3 dimension of bottom sash aluminum profiles 4,332 was selected for analysis.FindingsThe results indicated a reduction in DPMO from 89,649 to 15,659, sigma level was improved from 2.84 to 3.65, process yield was improved from 91.04% to 98.43% and cost was reduced from U$75,972 to U$13,250.9 (i.e. a saving of U$62,721). Studying and improving the sigma level of the extrusion process would yield fewer defective products and consequently fewer customer complaints. A validation process which has been conducted during the year 2019 showed a consistent improvement that aligns with the first stage of improvement made on October 1, 2018.Research limitations/implicationsThis study focuses on only one critical quality characteristic (CTQ), namely, a geometry CTQ of D3 dimension of bottom sash aluminum profiles 4,332 produced by NAPCO was selected for analysis.Practical implicationsThis study would be useful for researchers and practitioners to improve the process capability in aluminum profiles manufacturing industries in general and hot extrusion processes in particular.Originality/valueMany previous studies on applying LSS-DMAIC methodology have been conducted in aluminum industries in developed countries. According to the literature, it is highly recommended to have more case studies of applying LSS-DMAIC in different industries in developing countries. NAPCO is the only aluminum manufacturing plant in Palestine that hotly extrudes and coats aluminum profiles. Hence, the present study is the first of its kind in NAPCO and in Palestine. Projecting the assessment of the impact of process improvement opportunities and capability analyses into monetary measures are also innovative.

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Section: Previous Studiesmentioning

confidence: 99%

“…The study resulted in improved sigma level, decreased parts per millions (ppm) levels and hence improved capability indices. One more study by Bucko et al. (2020) applied LSS methodology in the production process of welded chassis frames in Czech Republic.…”

Section: Literature Reviewmentioning

confidence: 99%

A case study on implementing Lean Six Sigma: DMAIC methodology in aluminum profiles extrusion process

Araman¹,

Saleh

2022

TQM

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“…En cambio, al aplicar una metodología como Six Sigma, siempre busca mejorar los procesos y tiene el objetivo de reducir las inconformidades. De esta forma se evitan gastos en reprocesos y se optimiza la producción [38,39,40,41,42].…”

Section: Discusiones Y Conclusionesunclassified

Continuous improvement methodologies in manufacturing firms: A systematic review of the literature 2016-2021

Llacctas-Espinoza,

Quezada-Albino,

Espejo-Peña

et al. 2023

Proceedings of the 21th LACCEI International Multi-Conference for Engineering, Education and Technology (LACCEI 2023): “Leaders

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This research aims to determine the methodologies of continuous improvement most used in manufacturing companies for the identification and solution of problems in the production process that may arise. Scientific articles were used using the SCOPUS, EBSCO and SCIENCE DIRECT databases. The filtering processes were considered to carry out this study with articles that respond to the question posed, with language in English and Spanish and are between 2016 and 2021. Similarly, some keywords were taken for the search such as improvement, methodology, manufacturing, continuous improvement. We selected 51 articles for this systematic review. The result obtained indicated that the Lean Manufacturing methodology is the most used by manufacturing companies in the last 6 years. Since this methodology reduces waste, costs and unproductive times, it satisfies the client's need and increases the productivity of a company making it more competent. Similarly, the 5S tool was identified as the most used to improve organization, order and cleanliness in the company. It is worth mentioning that one of the limitationspresented was the free access to documents that prevented a more accurate search.

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“…Therefore, there is a need to constantly adapt to new conditions, increase productivity, streamline production, or improve product quality to compete in international markets [2,3]. Companies are forced to implement various industrial engineering methods and techniques to introduce more efficient, effective, and sophisticated production [4][5][6]. They try to eliminate activities that bring no or low added value.…”

Section: Introductionmentioning

confidence: 99%

“…They try to eliminate activities that bring no or low added value. The company can achieve these set goals by implementing methodologies such as lean production or Six Sigma [6,7].…”

Section: Introductionmentioning

confidence: 99%

Design and Optimization of Production Line Layout Using Material Flows

Bučko,

Krejčí,

Hlavatý

et al. 2024

Machines

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Businesses are constantly trying to improve their production by looking for bottlenecks to improve their market position. The introduction and innovation of automated production lines is necessary for both labor shortages and productivity and quality reasons. A combination of precision, fluidity, and speed, that is the basic definition of a production line. With the advent of new technologies, production lines have also begun to continuously speed up and innovate. Innovation is the subject of this paper, where the problem of designing a completely new layout for a new production line in the food industry has been addressed. The aim of this paper was to create a design for the optimal layout of the production line in preselected production areas. Optimal use of the space allocated for production is very important for every company today.

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Application of Six Sigma Tools in the Production of Welded Chassis Frames

Cited by 5 publications

References 5 publications

A case study on implementing Lean Six Sigma: DMAIC methodology in aluminum profiles extrusion process

A case study on implementing Lean Six Sigma: DMAIC methodology in aluminum profiles extrusion process

Continuous improvement methodologies in manufacturing firms: A systematic review of the literature 2016-2021

Design and Optimization of Production Line Layout Using Material Flows

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