Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 13

Six Sigma Related Publications

13 Six Sigma-Based Optimization of Shrinkage Accuracy in Injection Molding Processes

Authors: Joseph C. Chen, Sky Chou

Abstract:

This paper focuses on using six sigma methodologies to reach the desired shrinkage of a manufactured high-density polyurethane (HDPE) part produced by the injection molding machine. It presents a case study where the correct shrinkage is required to reduce or eliminate defects and to improve the process capability index Cp and Cpk for an injection molding process. To improve this process and keep the product within specifications, the six sigma methodology, design, measure, analyze, improve, and control (DMAIC) approach, was implemented in this study. The six sigma approach was paired with the Taguchi methodology to identify the optimized processing parameters that keep the shrinkage rate within the specifications by our customer. An L9 orthogonal array was applied in the Taguchi experimental design, with four controllable factors and one non-controllable/noise factor. The four controllable factors identified consist of the cooling time, melt temperature, holding time, and metering stroke. The noise factor is the difference between material brand 1 and material brand 2. After the confirmation run was completed, measurements verify that the new parameter settings are optimal. With the new settings, the process capability index has improved dramatically. The purpose of this study is to show that the six sigma and Taguchi methodology can be efficiently used to determine important factors that will improve the process capability index of the injection molding process.

Keywords: Six Sigma, shrinkage, Taguchi parameter design, injection molding

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12 Taguchi-Based Six Sigma Approach to Optimize Surface Roughness for Milling Processes

Authors: Joseph C. Chen, Sky Chou

Abstract:

This paper focuses on using Six Sigma methodologies to improve the surface roughness of a manufactured part produced by the CNC milling machine. It presents a case study where the surface roughness of milled aluminum is required to reduce or eliminate defects and to improve the process capability index Cp and Cpk for a CNC milling process. The six sigma methodology, DMAIC (design, measure, analyze, improve, and control) approach, was applied in this study to improve the process, reduce defects, and ultimately reduce costs. The Taguchi-based six sigma approach was applied to identify the optimized processing parameters that led to the targeted surface roughness specified by our customer. A L9 orthogonal array was applied in the Taguchi experimental design, with four controllable factors and one non-controllable/noise factor. The four controllable factors identified consist of feed rate, depth of cut, spindle speed, and surface roughness. The noise factor is the difference between the old cutting tool and the new cutting tool. The confirmation run with the optimal parameters confirmed that the new parameter settings are correct. The new settings also improved the process capability index. The purpose of this study is that the Taguchi–based six sigma approach can be efficiently used to phase out defects and improve the process capability index of the CNC milling process.

Keywords: Six Sigma, surface roughness, CNC machining, Taguchi methodology

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11 Framework Study on Single Assembly Line to Improve Productivity with Six Sigma and Line Balancing Approach

Authors: Inaki Maulida Hakim, T. Yuri M. Zagloel, Astari Wulandari

Abstract:

Six sigma is a framework that is used to identify inefficiency so that the cause of inefficiency will be known and right improvement to overcome cause of inefficiency can be conducted. This paper presents result of implementing six sigma to improve piston assembly line in Manufacturing Laboratory, Universitas Indonesia. Six sigma framework will be used to analyze the significant factor of inefficiency that needs to be improved which causes bottleneck in assembly line. After analysis based on six sigma framework conducted, line balancing method was chosen for improvement to overcome causative factor of inefficiency which is differences time between workstation that causes bottleneck in assembly line. Then after line balancing conducted in piston assembly line, the result is increase in efficiency. Efficiency is shown in the decreasing of Defects per Million Opportunities (DPMO) from 900,000 to 700,000, the increasing of level of labor productivity from 0.0041 to 0.00742, the decreasing of idle time from 121.3 seconds to 12.1 seconds, and the increasing of output, which is from 1 piston in 5 minutes become 3 pistons in 5 minutes.

Keywords: Productivity, Six Sigma, Efficiency, Improvement, line balancing, assembly line, workstation

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10 Analysis of Critical Success Factors of Six Sigma in Pakistani Small and Medium-Sized Enterprises

Authors: Cahit Ali Bayraktar, Zanjbeel Tabassum, Asfa Muhammad Din, Murat Durucu

Abstract:

Six Sigma is a widely adapted quality improvement methodology applied throughout the world. Through this paper, an attempt has been made to identify Critical Success Factors (CSF) for successful implementation of Six Sigma in Pakistani Small and Medium-sized Enterprises (SMEs). A survey methodology was used to collect the data from SMEs in Pakistan. The results of this exploratory empirical research reflect the importance of different CSFs of Six Sigma implementation in SMEs in Pakistan. On the basis of extracted factors, a framework has been proposed for successful Six Sigma implementation in Pakistani SMEs. This study will provide a base for Pakistani SMEs and future researchers working in Six Sigma implementation and help them to prepare a road map to eradicate the hurdles in Six Sigma implementation.

Keywords: Six Sigma, Pakistan, critical success factors, small and medium-sized enterprises

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9 Identifying the Barriers behind the Lack of Six Sigma Use in Libyan Manufacturing Companies

Authors: Osama Elgadi, Martin Birkett, Wai Ming Cheung

Abstract:

This paper investigates the barriers behind the underutilisation of six sigma in Libyan manufacturing companies (LMCs). A mixed-method methodology is proposed, starting by conducting interviews to collect qualitative data followed by the development of a questionnaire to obtain quantitative data. The focus of this paper is on discussing the findings of the interview stage and how these can be used to further develop the questionnaire stage. The interview results showed that only four key barriers were highlighted as being encountered by LMCs. With a difference in terms of their significance, these factors were identified, and placed in descending order according to their importance, namely: “Lack of top management commitment”, “Lack of training”, “Lack of knowledge about six sigma”, and “Culture effect”. The findings also showed that some barriers which, were found in previous studies of six sigma implementation were not considered as barriers to LMCs but can, in fact, be considered as success factors or enablers for six sigma adoption. These factors were identified as: “sufficiency of time and financial resources”; “customers unsatisfied”; “good communication between all departments in the company”; “we are certain about its results and benefits to our company and unhappy with the current quality system”. These results suggest that LMCs face fewer barriers to adopting six sigma than many well-established global companies operating in other countries and could take advantage of these successful factors by developing and implementing a six sigma framework to improve their product quality and competitiveness.

Keywords: Six Sigma, barriers, interview, Libyan manufacturing companies

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8 Six Sigma Assessment in the Latvian Commercial Banking Sector

Authors: I. Erins, J. Erina

Abstract:

The goals of the present research are to estimate Six Sigma implementation in Latvian commercial banks and to identify the perceived benefits of its implementation. To achieve the goals, the authors used sequential explanatory method. To obtain empirical data, the authors have developed the questionnaire and adapted it for the employees of Latvian commercial banks. The questions are related to Six Sigma implementation and its perceived benefits. The questionnaire mainly consists of closed questions, the evaluation of which is based on 5 point Likert scale. The obtained empirical data has shown that of the two hypotheses put forward in the present research – Hypothesis 1 – has to be rejected, while Hypothesis 2 has been partially confirmed. The authors have also faced some research limitations related to the fact that the participants in the questionnaire belong to different rank of the organization hierarchy.

Keywords: Six Sigma, Quality, commercial banking sector, Latvia

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7 Identification of Critical Success Factors in Non-Formal Service Sector Using Delphi Technique

Authors: Amol A. Talankar, Prakash Verma, Nitin Seth

Abstract:

The purpose of this study is to identify the critical success factors (CSFs) for the effective implementation of Six Sigma in non-formal service Sectors.

Based on the survey of literature, the critical success factors (CSFs) for Six Sigma have been identified and are assessed for their importance in Non-formal service sector using Delphi Technique. These selected CSFs were put forth to the panel of expert to cluster them and prepare cognitive map to establish their relationship.

All the critical success factors examined and obtained from the review of literature have been assessed for their importance with respect to their contribution to Six Sigma effectiveness in non formal service sector.

The study is limited to the non-formal service sectors involved in the organization of religious festival only. However, the similar exercise can be conducted for broader sample of other non-formal service sectors like temple/ashram management, religious tours management etc.

The research suggests an approach to identify CSFs of Six Sigma for Non-formal service sector. All the CSFs of the formal service sector will not be applicable to Non-formal services, hence opinion of experts was sought to add or delete the CSFs. In the first round of Delphi, the panel of experts has suggested, two new CSFs-“competitive benchmarking (F19) and resident’s involvement (F28)”, which were added for assessment in the next round of Delphi.  One of the CSFs-“fulltime six sigma personnel (F15)” has been omitted in proposed clusters of CSFs for non-formal organization, as it is practically impossible to deploy full time trained Six Sigma recruits.

Keywords: Six Sigma, Quality assurance, Critical success factors (CSFs), non-formal service sectors

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6 Analysis of Six Sigma in the Aerospace Industry

Authors: Masimuddin Mohd Khaled

Abstract:

This paper subsidizes to the discussion of Six Sigma in the Aerospace Industry. The main aim of this report is to study the literature review of Six Sigma emphasizing on the aerospace industry. The implementation of Six Sigma stages are studied and how the improvement cycle ‘Define, Measure, Analyze, Improve and Control cycle’ (DMAIC) and the design process is ‘Define, Measure, Analyze, Design and Verify cycle’ (DMADV) is used. The focus is also done by studying how the implementation of Six Sigma on an aerospace company has brought a positive effect to the company.

Keywords: Aerospace, Six Sigma, DMAIC, DMADV

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5 Six Sigma in Mexican Manufacturing Companies

Authors: DIEGO TLAPA, Jorge Limón, Yolanda Báez, Julián Aguilar

Abstract:

This work is about Six Sigma (SS) implementation in Mexico by using an empirical study. Main goals are to analyze the degree of importance of the Critical Success Factors (CSFs) of SS and to examine if these factors are grouped in some way. A literature research and a survey were conducted to capture SS practitioner’s viewpoint about CSFs in SS implementation and their impact on the performance within manufacturing companies located in Baja California, Mexico. Finally, a Principal Component Analysis showed that nine critical success factors could be grouped in three components, which are: management vision, implementation strategy, and collaborative team. In the other hand, SS’s success is represented by cost reduction, variation reduction, experience and self-esteem of the workers, and quality improvement. Concluding remarks arising from the study are that CSFs are changing through time and paying attention to these nine factors can increase SS’s success likelihood.

Keywords: Six Sigma, Factor Analysis, critical success factors

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4 Improving Patients Discharge Process in Hospitals by using Six Sigma Approach

Authors: Mahmoud A. El-Banna

Abstract:

The need to increase the efficiency of health care systems is becoming an obligation, and one of area of improvement is the discharge process. The objective of this work is to minimize the patients discharge time (for insured patients) to be less than 50 minutes by using six sigma approach, this improvement will also: lead to an increase in customer satisfaction, increase the number of admissions and turnover on the rooms, increase hospital profitability.Three different departments were considered in this study: Female, Male, and Paediatrics. Six Sigma approach coupled with simulation has been applied to reduce the patients discharge time for pediatrics, female, and male departments at hospital. Upon applying these recommendations at hospital: 60%, 80%, and 22% of insured female, male, and pediatrics patients respectively will have discharge time less than the upper specification time i.e. 50 min.

Keywords: Simulation, Healthcare, Six Sigma, hospitals, Process Improvement, patients, Discharge Time

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3 Integrating the Theory of Constraints and Six Sigma in Manufacturing Process Improvement

Authors: Kai Jin, Hyder Abdul-Razzak, Yousri Elkassabgi, Hong Zhou, Aaron Herrera

Abstract:

Six Sigma is a well known discipline that reduces variation using complex statistical tools and the DMAIC model. By integrating Goldratts-s Theory of Constraints, the Five Focusing Points and System Thinking tools, Six Sigma projects can be selected where it can cause more impact in the company. This research defines an integrated model of six sigma and constraint management that shows a step-by-step guide using the original methodologies from each discipline and is evaluated in a case study from the production line of a Automobile engine monoblock V8, resulting in an increase in the line capacity from 18.7 pieces per hour to 22.4 pieces per hour, a reduction of 60% of Work-In-Process and a variation decrease of 0.73%.

Keywords: Six Sigma, System Thinking, Constraint Management, Manufacturing Process Improvement

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2 Six Sigma Process and its Impact on the Organizational Productivity

Authors: Masoud Hekmatpanah, Mohammad Sadroddin, Saeid Shahbaz, Farhad Mokhtari, Farahnaz Fadavinia

Abstract:

The six sigma method is a project-driven management approach to improve the organization-s products, services, and processes by continually reducing defects in the organization. Understanding the key features, obstacles, and shortcomings of the six sigma method allows organizations to better support their strategic directions, and increasing needs for coaching, mentoring, and training. It also provides opportunities to better implement six sigma projects. The purpose of this paper is the survey of six sigma process and its impact on the organizational productivity. So I have studied key concepts , problem solving process of six sigmaas well as the survey of important fields such as: DMAIC, six sigma and productivity applied programme, and other advantages of six sigma. In the end of this paper, present research conclusions. (direct and positive relation between six sigma and productivity)

Keywords: Theory, Project Management, Productivity, Six Sigma, Quality

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1 The Application of Six Sigma to Integration of Computer Based Systems

Authors: Zenon Chaczko, Essam Rahali, Rizwan Tariq

Abstract:

This paper introduces a process for the module level integration of computer based systems. It is based on the Six Sigma Process Improvement Model, where the goal of the process is to improve the overall quality of the system under development. We also present a conceptual framework that shows how this process can be implemented as an integration solution. Finally, we provide a partial implementation of key components in the conceptual framework.

Keywords: Six Sigma, System Integration, software quality

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