Reducing rejection and rework by application of Six Sigma methodology in manufacturing process

Gijo, E.V.; Scaria, Johny

doi:10.1504/ijssca.2010.034857

Cited by 45 publications

(25 citation statements)

References 13 publications

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“…Now, treating these S/N ratio values as response, ANOVA was performed to identify the contribution of each of the factors to the variability in performance of the product (Gijo and Scaria 2010). Now, treating these S/N ratio values as response, ANOVA was performed to identify the contribution of each of the factors to the variability in performance of the product (Gijo and Scaria 2010).…”

Section: Discussionmentioning

confidence: 99%

Product design by application of Taguchi's robust engineering using computer simulation

Gijo

Scaria

2012

International Journal of Computer Integrated Manufacturing

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This article discusses the application of Taguchi's robust parameter design (RPD) approach in the design of a motor in a large electrical company in India. There used to be specific customer requirements related to temperature rise and low efficiency of the existing model of motor, which the organisation was unable to meet. Taguchi's parameter design approach was successfully applied to derive the optimum design. Orthogonal arrays were used to design the experiments with 13 control factors, each at 3 levels and 2 noise factors. The experimentation was carried out by a computer simulation and the data were analysed using signal-to-noise ratio method. From the analysis of variance along with main effect plots, the optimum factor level combination for the new product was reached. As per the optimum design, prototype was made and tested with respect to the customer requirements and was found to give satisfactory results for all performance characteristics. This approach has given the result in just 10 weeks' time, whereas the traditional design approach used to take 12 to 15 months to arrive at the optimum design values.

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Section: Discussionmentioning

confidence: 99%

Product design by application of Taguchi's robust engineering using computer simulation

Gijo

Scaria

2012

International Journal of Computer Integrated Manufacturing

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“…The time frame given by the management to achieve this target was approximately five months. Based on this understanding, the team decided to perform a Supplier‐Input‐Process‐Output‐Customer (SIPOC) analysis for this project, so that every team member had good clarity in the process steps and project scope . During the preparation of SIPOC, people from all the processes in OPD were actively participating.…”

Section: Lss In Opdmentioning

confidence: 99%

Reducing Patient Waiting Time in Outpatient Department Using Lean Six Sigma Methodology

Gijo

Antony

2013

Quality & Reliability Eng

130

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This article addresses the issue of longer patient waiting time in the outpatient department (OPD) of a super specialty hospital attached to a manufacturing company in India. Due to longer waiting times at OPD, employees need to be away from the workplace for a longer duration. This problem was addressed through the Lean Six Sigma (LSS) methodology. The process, starting from registration of a patient to dispensing of medicine, was included in the project. The non-value added steps in the process were identified, and actions were initiated. A cause and effect diagram was prepared for high patient waiting time, and causes were validated with the help of data collected from the process. Statistical tools such as Kruskal-Wallis test, Box -Cox transformation, Control charts, normality test, etc., were used within the LSS methodology not only to identify the causes but also to sustain the improvements. As a result of this project, the average waiting time reduced from 57 min to 24.5 min and the standard deviation was reduced to 9.27 from 31.15 min. This will help the hospital to serve patients better and faster, which, in turn, will lead to a reduction in delay of treatment and a faster recovery of patients. The productivity loss due to absenteeism of employees from the workplace could be reduced. Generally, in an Indian health care scenario, most of the activities were dependent on individual doctors rather than processes. This project has helped the clinicians and the hospital management to identify the weak areas in the process for improvement. Because of the implemented solutions, understanding the history of past treatments and medications of the patients was easy for the doctors. Also, the practical validity of deploying LSS in a healthcare scenario was justified with this study.

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“…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].…”

Section: Introductionmentioning

confidence: 99%

Assessing the Success of Six Sigma: An Empirical Study

2015

International Conference on Advancements and Recent Innovations in Mechanical, Production and Industrial Engineering

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Abstract-In response to the ever increasing demand of customer and prompt changing economic conditions, various industrial engineering and quality management strategies such as ISO 9000, total quality management (TQM), lean manufacturing, manufacturing recourse planning, modular design, reengineering, flexible manufacturing system (FMS), etc., are adopted by the corporations to compete in the current competitive market. However, from the last three decades a new paradigm, known as "Six Sigma", has made its prime impact in the area of manufacturing strategies to solve the problems related to the quality and productivity. In this paper, a case of Indian foundry unit has been presented to explore the effectiveness of six sigma methodology. The DMAIC (Define-Measure-Analyze-ImproveControl) approach of six sigma has been followed here to reduce percentage of defects in green sand casting process. In addition, Taguchi method of parameter design is used to set the optimal process parameters in the 'Improve phase'. Analysis of variance (ANOVA) is then performed to find the optimal parameter levels and to identify the statistical significance and contribution of each factor on the casting defects. Finally, a confirmation test is performed using the optimal parameter setting, which shows that the casting defects can be minimized, effectively. The results show that after successful deployment of six sigma, the percentage of casting defects is reduced by 25.44%.

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Reducing rejection and rework by application of Six Sigma methodology in manufacturing process

Cited by 45 publications

References 13 publications

Product design by application of Taguchi's robust engineering using computer simulation

Product design by application of Taguchi's robust engineering using computer simulation

Reducing Patient Waiting Time in Outpatient Department Using Lean Six Sigma Methodology

Assessing the Success of Six Sigma: An Empirical Study

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