Energy paybacks of six-sigma: A case study of manufacturing industry in India

Abstract

Industries, nowadays, are concerned about energy consumption and ever narrowing rules of emissions by the governments. Therefore, a race to clean; green and less energy consuming manufacturing is going on throughout the world. But in authors' perspective, the major part of energy exploitation lies in the production of a rejected product. Therefore alongside the use of energy saving processes and machinery, industry should primarily look for rejection reduction. This, apart from energy saving and profitability, will add to the moral responsibility of every person toward nature. Here in this paper, authors describe a case study in which the increased rejection rate of a part of cycle chain assembly is controlled by the application of Six Sigma. Six Sigma, from many years has proved to be an ultimate solution when it comes to the application part in manufacturing industries. It's very generic and easily applicable methodology has drawn tremendous positive results throughout the world. A financial gain of INR 0.267 million was yielded by implying six-sigma approach. In a move toward energy saving, the money saved by the project was used for green manufacturing to promote energy conservation.

Statistics for industries: A sophisticated approach

“…This can be achieved by inputting the continuous effort in understanding the process and managing the system associated with the process (Kaushik & Mittal, 2017). In order to achieve customer satisfaction researchers and industrialists around the world have worked over various tools and techniques like Total Quality Management (TQM), Quality circles (Mittal and Prajapati 2014), APQP Kaushik et al, 2011), Shainin system , Quality Awards, Fuzzy logic (Mittal et al, 2016a), Total Preventive Maintenance (TPM), Business Process Reengineering (Mittal et al, 2016b), Lean and Six Sigma Kaushik et al, 2016). One of the most popular techniques named above is Six-Sigma.…”

“…One of the most popular techniques named above is Six-Sigma. It aims to find out the basic causes in process and eliminate them to achieve business excellence (Kaushik et al, 2016). The procedure includes the formation of team within the organization and using statistics along with traditional quality control tools (Kaushik & Mittal, 2015).…”

Analysis of mechanical properties of jute fiber strengthened epoxy/polyester composites

“…It is a very simple and organized approach through which the design parameters can be optimized while reducing the overall testing time and experimental cost (Kaushik et al, 2016). It consists of two important tools.…”

Initiatives of six-sigma in an automotive ancillary unit: A case study

“…SME sector needs immediate attention due to its participation in global progress in form of breakthrough strategy other than Statistical Process Control (SPC) (Kaushik et al, 2017a). In order to achieve customer satisfaction, researchers and industrialists around the world have worked over various tools (Kaushik et al, 2017b,c) and techniques like Total Quality Management (TQM), Quality circles (Mittal & Prajapati 2014), APQP Mittal et al, , 2012, Shainin system , Quality Function Deployment (QFD) Tewari et al, 2017), Decision Tree Analysis (Mittal et al, 2017;Mittal et al, 2017a), Fuzzy logic , Total Preventive Maintenance (TPM), Business Process Reengineering , Lean and Six Sigma Kaushik et al, 2016a). The most popular of the techniques named above is Six-Sigma.…”