Success of manufacturing industries – Role of Six Sigma

Abstract

Abstract. Six Sigma is a phenomenal quality management concepts which has helped many organizations to overcome quality crisis in the recent past. Six Sigma is observed as a very promising quality management tool for any organization to make its presence felt in the corporate world as it emphasizes on obtaining a fruitful solution to improve accuracy, reduce defect thereby reduce the cost and improve profits. The main objective of this investigation is to unearth the extent to which the companies have been benefitted due to Six Sigma implementation. This article presents the results based on the analysis of collective opinion of employees of various Indian manufacturing industries that have implemented Six Sigma. This research also examines interrelationship among various parameters defined in the research. The research revealed that industries are benefitted irrespective of their nature in terms of their growth, financial benefits, productivity and satisfaction of the customer. However, peoples' equity that deals with the benefits that employees obtain after Six Sigma implementation is not certain. The research also revealed the existence of strong interrelationship among various parameters used to measure the success of Six Sigma.

Methodology for Data-Informed Process Improvement to Enable Automated Manufacturing in Current Manual Processes

“…A corrugated box manufacturing company reduced 22.7% of its waste by applying the DMAIC Six Sigma framework [22]. Implementation of Six Sigma in automobile industries and thermal power plants have also shown positive outcomes [23,24]. Table 1 summarizes the methodologies described in various research publications on the subject.…”

“…Develop a new model to bridge the gaps, such as inefficient methods or tools, in process improvement methodologies IDDOV (Identity, Define, Develop, Optimize, Verify) [22] Corrugated boxes manufacturer Reduce waste during production DMAIC [23] Automobile industry…”

“…Digitization of data produces large quantities of unorganized data, which can be difficult and time consuming to analyze manually. The Lean and Six Sigma implementations listed in Table 1 in Section 2.1 were specific to particular issues in their respective industries with no automation intention [16][17][18][19][20][21][22][23][24][25][26][27][28]. The Strategic Lean Six Sigma Framework proposed to reduce build time in an aerospace industry that required validation from new areas within the industry [25].…”

Management and Production Engineering Review

“…2. Nonthaleerak (2008), Thailand [30] various industries Exploring weakness in six sigma implementations & key success factor Sardeshpan de & Khairnar (2014), India [31] automotive industry Improving the quality of four wheeler platform truck Venkatesh & Sumangala (2018), India [32] various industries Investigating companies that have been benefitted to Six Sigma implementation Flifel et.al. (2017), Serbia [3] various industries Identification potential Six Sigma project & recommendation of techniques and tools from the literature Rathilall & Sigh (2018), South Africa [33] automotive industry Investigating the integration of Lean & Six Sigma tools in automotive component manufacturing Kumar & Naidu (2012), India [34] garment industry Absenteeism can be controlled by implementing LSS More & Pawar (2011), India [17] textile industry Implementation of Six Sigma QMS with ISO resulted in competitiveness & performance improvement Ganguly (2012), India [35] aluminum industry Addressing the problem in the aluminum industry by applying six sigma principles Syafwiratama et al (2017), Indonesia [36] fiber industry Reducing NC products in polyester short cut production & increase capability from 2.2 to 3.1 sigma Malek & Desai (2015), India [37] casting industry Focus on providing a path for initiating six sigma Naidu (2011), India [38] steel industry Reducing down time machines by obtaining optimum preventive maintenance frequency Gandhi et al (2019), India [39] automotive industry Identification of blowholes occurrence & defect reduction from 28,111 to 9,708 PPM Kosieradzka & Ciechańska (2018), Poland [40] industrial automation enterprise…”

Algorithm for Process Innovation by Increasing Ideality

“…The result is the reduction in defects to a maximum of 3.4 defects per one million opportunities. A DMAIC (define, measure, analyze, improve, control) improvement cycle is used to apply the Six Sigma method [2][3][4][25][26][27]. A combination of Lean and Six Sigma is often used and is referred to as Lean/Six Sigma (LSS).…”