Six Sigma practice for quality improvement – A case study of Indian auto ancillary unit

Sambhe, Rajeshkumar U.

doi:10.9790/1684-0442642

Cited by 11 publications

(5 citation statements)

References 7 publications

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“…(Sambhe, 2012) 15) successfully implemented Six Sigma at a mid-sized auto auxiliary unit that consisted of between 350 and 400 people. The technique was used on one of the product assemblies with the purpose of reducing the number of defects, which are important to the clients, and the installation of the methodology has resulted in a large financial blow to the bottom line of the company.…”

Section: Literature Reviewmentioning

confidence: 99%

Reducing Oil Leakage in Heavy Duty Transformers Made in Small-Scale Manufacturing Industry Through Six Sigma DMAIC: A Case Study for Jaipur

Neeru¹,

Rajput²,

Patil³

2023

Evergreen

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The purpose of this study is to address the issue of oil leaks in transformers manufactured by small scale enterprises in Jaipur, India. The DMAIC technique of Six Sigma methodology was used to analyze the problem and develop solutions. The study focused on both newly manufactured and warranty-period transformers, and a number of design tools were used, including SIPOC, DEMATEL, Ishikawa diagram, P-chart, Pareto chart, and cause and effect matrix and diagram. The findings showed that Six Sigma can be an effective tool for small scale industries and their customers in resolving product issues. However, limitations of the study include the potential for inaccurate findings due to improper data gathering, as the available company data for Six Sigma analysis was minimal.This study highlights the importance of adopting Six Sigma principles in small-scale manufacturing sectors, particularly in the production of oil-filled transformers, where a lack of research has been reported globally. By investigating the challenges faced by customers during and after the purchasing process, the study aims to assist companies entering the manufacturing industry by improving working conditions and reducing replication issues in the production process. The study's contribution is to fill the gap in research on the application of Six Sigma in the small-scale transformer industry and provide valuable insights for companies operating in this sector.

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Section: Literature Reviewmentioning

confidence: 99%

Reducing Oil Leakage in Heavy Duty Transformers Made in Small-Scale Manufacturing Industry Through Six Sigma DMAIC: A Case Study for Jaipur

Neeru¹,

Rajput²,

Patil³

2023

Evergreen

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“…Application of Six Sigma methodology brought up the process sigma level to 5.46 from 1.40 by reduction in bush diameter variation which was equivalent to monetary saving of INR 0.288m per annum. Sambhe (2012) have applied Six Sigma at mid-sized auto ancillary unit consisting of 350-400 employees. The methodology was executed on one of product assembly for trimming down defects level which are critical to customers and its implementation has had a significant financial hit on the bottom-line of the enterprise.…”

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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“…Quality related costs have been measured to be as much as 40% of sales in some organizations. These costs, known as the Costs of Poor Quality (COPQ), can occur in many different ways ranging from scrapping of work in process, customer returns after the products [3].The six sigma method includes measured and reported financial results, uses additional, more advanced data analysis tools, focuses on customer concerns, and uses project management tools and methodology [2]. Lean Six Sigma is a business improvement methodology which combines tools from both Lean Manufacturing and Six Sigma.…”

Section: Literature Reviewmentioning

confidence: 99%

Application of Lean Six Sigma Tools for Reduction of Defects in Pump Manufacturing

Ramakrishnan

Jayaprakash

2015

AMM

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Lean Six Sigma tools are widely being applied in various manufacturing units of different sizes; still there is an apprehension among the industry regarding the benefits reaped from the implementation of this tool. Under this background, this paper attempts to explain the benefits of these tools implemented in a medium scale unit to improve a particular process. The various steps involved in implementation and the results are analyzed for the purpose of this study and explained in this paper.

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Six Sigma practice for quality improvement – A case study of Indian auto ancillary unit

Cited by 11 publications

References 7 publications

Reducing Oil Leakage in Heavy Duty Transformers Made in Small-Scale Manufacturing Industry Through Six Sigma DMAIC: A Case Study for Jaipur

Reducing Oil Leakage in Heavy Duty Transformers Made in Small-Scale Manufacturing Industry Through Six Sigma DMAIC: A Case Study for Jaipur

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

Application of Lean Six Sigma Tools for Reduction of Defects in Pump Manufacturing

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