Search results for: problems faced in six sigma implementation

Authors: Rajeshkumar U. Sambhe

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Large scale Indian manufacturers started implementing Six Sigma to their supply core to fulfill the endless need of high quality products. As well, they initiated encouraging their suppliers to apply the well-ascertain SS management practice and kept no resource for supplier enterprises, generally small midsized enterprises to think for the admittance of Six Sigma as a quality promotion drive. There are many issues to study for requisite changes before the introduction of Six Sigma in auto SMEs. This paper converges on impeding factors while implementing SS drive and also pinpoints the gains achieved through successful implementation. The result of this study suggest some operational guidelines for effective implementation of Six Sigma from evidences acquired through research questionnaire and interviews with industrial professionals, apportioned to assort auto sector mid-sized enterprises (MSEs) in India.

Keywords: Indian automotive SMEs, quality management practices, six sigma imperatives, problems faced in six sigma implementation, benefits, some guidelines for implementation.

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

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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: Critical success factors, small and medium-sized enterprises, Six Sigma, Pakistan.

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Authors: J. Erina, I. Erins

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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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Authors: Masimuddin Mohd Khaled

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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: Six Sigma, DMAIC, DMADV, aerospace.

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

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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: Six sigma, project management, quality, theory, productivity.

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Authors: S. Homrossukon, A. Anurathapunt

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This is an application research presenting the improvement of production quality using the six sigma solutions and the analyses of benefit-cost ratio. The case of interest is the production of tile-concrete. Such production has faced with the problem of high nonconforming products from an inappropriate surface coating and had low process capability based on the strength property of tile. Surface coating and tile strength are the most critical to quality of this product. The improvements followed five stages of six sigma solutions. After the improvement, the production yield was improved to 80% as target required and the defective products from coating process was remarkably reduced from 29.40% to 4.09%. The process capability based on the strength quality was increased from 0.87 to 1.08 as customer oriented. The improvement was able to save the materials loss for 3.24 millions baht or 0.11 million dollars. The benefits from the improvement were analyzed from (1) the reduction of the numbers of non conforming tile using its factory price for surface coating improvement and (2) the materials saved from the increment of process capability. The benefit-cost ratio of overall improvement was high as 7.03. It was non valuable investment in define, measure, analyses and the initial of improve stages after that it kept increasing. This was due to there were no benefits in define, measure, and analyze stages of six sigma since these three stages mainly determine the cause of problem and its effects rather than improve the process. The benefit-cost ratio starts existing in the improve stage and go on. Within each stage, the individual benefitcost ratio was much higher than the accumulative one as there was an accumulation of cost since the first stage of six sigma. The consideration of the benefit-cost ratio during the improvement project helps make decisions for cost saving of similar activities during the improvement and for new project. In conclusion, the determination of benefit-cost ratio behavior through out six sigma implementation period provides the useful data for managing quality improvement for the optimal effectiveness. This is the additional outcome from the regular proceeding of six sigma.

Keywords: Six Sigma Solutions, Process Improvement, QualityManagement, Benefit Cost Ratio

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Authors: E. Farshidi, N. Ahmadpoor

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In this paper, a alternative structure method for continuous time sigma delta modulator is presented. In this modulator for implementation of integrators in loop filter second generation current conveyors are employed. The modulator is designed in CMOS technology and features low power consumption (<2.8mW), low supply voltage (±1.65), wide dynamic range (>65db), and with 180khZ bandwidth. Simulation results confirm that this design is suitable for data converters.

Keywords: Current Conveyor, continuous, sigma delta, MOS, modulator

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Authors: Soon Jai Yi, Sun-Hong Kim, Hang-Geun Jeong, Seong-Ik Cho

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This paper presents a method of reducing the feedback delay time of DWA(Data Weighted Averaging) used in sigma-delta modulators. The delay time reduction results from the elimination of the latch at the quantizer output and also from the falling edge operation. The designed sigma-delta modulator improves the timing margin about 16%. The sub-circuits of sigma-delta modulator such as SC(Switched Capacitor) integrator, 9-level quantizer, comparator, and DWA are designed with the non-ideal characteristics taken into account. The sigma-delta modulator has a maximum SNR (Signal to Noise Ratio) of 84 dB or 13 bit resolution.

Keywords: Sigma-delta modulator, multibit, DWA

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Authors: Diego Tlapa, Jorge Limón, Yolanda Báez, Julián Aguilar

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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, Critical Success Factors, Factor Analysis.

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Authors: Zenon Chaczko, Essam Rahali, Rizwan Tariq

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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: Software Quality, Six Sigma, System Integration, 3SI Process, 3SI Conceptual Framework.

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Authors: P. Jelodarian , E. Farshidi

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In this paper, a new approach for design of a fully differential second order current mode continuous-time sigma-delta modulator is presented. For circuit implementation, square root domain (SRD) translinear loop based on floating-gate MOS transistors that operate in saturation region is employed. The modulator features, low supply voltage, low power consumption (8mW) and high dynamic range (55dB). Simulation results confirm that this design is suitable for data converters.

Keywords: Sigma-delta, current-mode, translinear loop, geometric mean, squarer/divider.

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Authors: Osama Elgadi, Martin Birkett, Wai Ming Cheung

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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, Libyan manufacturing companies, interview.

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Authors: Hanan Alshaher, Jinsheng Xu

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Large amounts of data on the web can provide valuable information. For example, product reviews help business owners measure customer satisfaction. Sentiment analysis classifies texts into two polarities: positive and negative. This paper examines movie reviews and tweets using a new term weighting scheme, called one-over-sigma (1/sigma), on benchmark datasets for sentiment classification. The proposed method aims to improve the performance of sentiment classification. The results show that 1/sigma is more accurate than the popular term weighting schemes. In order to verify if the entropy reflects the discriminating power of terms, we report a comparison of entropy values for different term weighting schemes.

Keywords: Sentiment analysis, term weighting scheme, 1/sigma.

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Authors: Abdelghani Dendouga, Nour-Eddine Bouguechal, Souhil Kouda, Samir Barra

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A behavioral model of a second order switchedcapacitor Sigma-Delta modulator is presented. The purpose of this work is the presentation of a behavioral model of a second order switched capacitor ΣΔ modulator considering (Error due to Clock Jitter, Thermal noise Amplifier Noise, Amplifier Slew-Rate, Non linearity of amplifiers, Gain error, Charge Injection, Clock Feedthrough, and Nonlinear on-resistance). A comparison between the use of MOS switches and the use transmission gate switches use is analyzed.

Keywords: Charge injection, clock feed through, Sigma Deltamodulators, Sigma Delta non-idealities, switched capacitor.

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

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

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Authors: A. Fakhfakh, N. Ksentini, M. Loulou, N. Masmoudi, J. J. Charlot

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Today, design requirements are extending more and more from electronic (analogue and digital) to multidiscipline design. These current needs imply implementation of methodologies to make the CAD product reliable in order to improve time to market, study costs, reusability and reliability of the design process. This paper proposes a high level design approach applied for the characterization and the optimization of Switched-Current Sigma- Delta Modulators. It uses the new hardware description language VHDL-AMS to help the designers to optimize the characteristics of the modulator at a high level with a considerably reduced CPU time before passing to a transistor level characterization.

Keywords: high level design, optimization, switched-Current Sigma-Delta Modulators, VHDL-AMS.

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Authors: Thiago Brito Bezerra, Mauro Lopes de Freitas, Waldir Sabino da Silva Júnior

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The Sigma-Delta A/D converters have been proposed as a practical application for A/D conversion at high rates because of its simplicity and robustness to imperfections in the circuit, also because the traditional converters are more difficult to implement in VLSI technology. These difficulties with conventional conversion methods need precise analog components in their filters and conversion circuits, and are more vulnerable to noise and interference. This paper aims to analyze the architecture, function and application of Analog-Digital converters (A/D) Sigma-Delta to overcome these difficulties, showing some simulations using the Simulink software and Multisim.

Keywords: Analysis, Oversampling Modulator, A/D converters, Sigma-Delta.

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Authors: Raif Parlakkaya, Huseyin Cetin, Halil Akmese, Mesut Murat Adabali

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As the economies of other countries in the Mediterranean Basin, the tourism sector in our country has a high denominator in economics. Tourism businesses, which are building blocks of tourism, sector faces with a variety of problems during their activities. These problems faced make business efficiency and competition conditions of the businesses difficult. Most of the problems faced by the tourism businesses and the information of consumers about consumers’ rights were used in this study, which is conducted to determine the problems of tourism businesses in the Central Anatolia Region. It is aimed to contribute the awareness of staff and executives working at tourism sector and to attract attention of businesses active concurrently with tourism sector and legislators.

Keywords: Financial Problems, The problems of Tourism businesses, Tourism Businesses, Tourism Sector in Turkey.

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

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

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Authors: Tajul Urus, S., Molla, A., Teoh, S.Y.

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A number of studies highlighted problems related to ERP systems, yet, most of these studies focus on the problems during the project and implementation stages but not during the postimplementation use process. Problems encountered in the process of using ERP would hinder the effective exploitation and the extended and continued use of ERP systems and their value to organisations. This paper investigates the different types of problems users (operational, supervisory and managerial) faced in using ERP and how 'feral system' is used as the coping mechanism. The paper adopts a qualitative method and uses data collected from two cases and 26 interviews, to inductively develop a casual network model of ERP usage problem and its coping mechanism. This model classified post ERP usage problems as data quality, system quality, interface and infrastructure. The model is also categorised the different coping mechanism through use of 'feral system' inclusive of feral information system, feral data and feral use of technology.

Keywords: Case Studies, Coping Mechanism, Post Implementation ERP system, Usage Problem

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

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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: Assembly line, efficiency, improvement, line balancing, productivity, six sigma, workstation.

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Authors: Sorore Benabid

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The Q-enhanced LC filters are the most used architecture in the Bandpass (BP) Continuous-Time (CT) Delta-Sigma (ΣΔ) modulators, due to their: high frequencies operation, high linearity than the active filters and a high quality factor obtained by Q-enhanced technique. This technique consists of the use of a negative resistance that compensate the ohmic losses in the on-chip inductor. However, this technique introduces a zero in the filter transfer function which will affect the modulator performances in term of Dynamic Range (DR), stability and in-band noise (Signal-to-Noise Ratio (SNR)). In this paper, we study the effect of this zero and we demonstrate that a calibration of the excess loop delay (ELD) is required to ensure the best performances of the modulator. System level simulations are done for a 2ndorder BP CT (ΣΔ) modulator at a center frequency of 300MHz. Simulation results indicate that the optimal ELD should be reduced by 13% to achieve the maximum SNR and DR compared to the ideal LC-based ΣΔ modulator.

Keywords: Continuous-time bandpass delta-sigma modulators, excess loop delay, on-chip inductor, Q-enhanced LC filter.

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Authors: Kazeem Oluwakemi Oseni, Kate Dingley

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e-Service has moved from the usual manual and traditional way of rendering services to electronic service provision for the public and there are several reasons for implementing these services, Airline ticketing have gone from its manual traditional way to an intelligent web-driven service of purchasing. Many companies have seen their profits doubled through the use of online services in their operation and a typical example is Hewlett Packard (HP) which is rapidly transforming their after sales business into a profit generating e-service business unit. This paper will examine the various challenges confronting e- Service adoption and implementation in Nigeria and also analyse lessons learnt from e-Service adoption and implementation in Asia to see how it could be useful in Nigeria which is a lower middle income country. From the analysis of the online survey data, it has been identified that the public in Nigeria are much aware of e-Services but successful adoption and implementation have been the problems faced.

Keywords: Adoption, Asia, e-Government Service, Implementation, Nigeria.

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Authors: A. Chahardah Cherik, E. Farshidi

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This paper presents a new configurable decimation filter for sigma-delta modulators. The filter employs the Pascal-s triangle-s theorem for building the coefficients of non-recursive decimation filters. The filter can be connected to the back-end of various modulators with different output accuracy. In this work two methods are shown and then compared from area occupation viewpoint. First method uses the memory and the second one employs Pascal-s triangle-s method, aiming to reduce required gates. XILINX ISE v10 is used for implementation and confirmation the filter.

Keywords: Decimation filter, sigma delta, Pascal's triangle'stheorem, memory

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Authors: Betül Gezer, Hacer Özden, Ahmet Tekcan, Osman Bizim

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Let p be a prime number, Fpbe a finite field and let Qpdenote the set of quadratic residues in Fp. In the first section we givesome notations and preliminaries from elliptic curves. In the secondsection, we consider some properties of rational points on ellipticcurves Ep,b: y2= x3+ b2 over Fp, where b ∈ F*p. Recall that theorder of Ep,bover Fpis p + 1 if p ≡ 5(mod 6). We generalize thisresult to any field Fnp for an integer n≥ 2. Further we obtain someresults concerning the sum Σ[x]Ep,b(Fp) and Σ[y]Ep,b(Fp), thesum of x- and y- coordinates of all points (x, y) on Ep,b, and alsothe the sum Σ(x,0)Ep,b(Fp), the sum of points (x, 0) on Ep,b.

Keywords: Elliptic curves over finite fields, rational points on elliptic curves.

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Authors: Milan Hladik

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The symmetric solution set Σ sym is the set of all solutions to the linear systems Ax = b, where A is symmetric and lies between some given bounds A and A, and b lies between b and b. We present a contractor for Σ sym, which is an iterative method that starts with some initial enclosure of Σ sym (by means of a cartesian product of intervals) and sequentially makes the enclosure tighter. Our contractor is based on polyhedral approximation and solving a series of linear programs. Even though it does not converge to the optimal bounds in general, it may significantly reduce the overestimation. The efficiency is discussed by a number of numerical experiments.

Keywords: Linear interval systems, solution set, interval matrix, symmetric matrix.

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Authors: Mahmoud A. El-Banna

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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: Discharge Time, Healthcare, Hospitals, Patients, Process Improvement, Six Sigma, Simulation

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Authors: Boram Kim, Shigeyasu Uno, Kazuo Nakazato

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Continuous-time delta-sigma analog digital converter (ADC) for radio frequency identification (RFID) complementary metal oxide semiconductor (CMOS) biosensor has been reported. This delta-sigma ADC is suitable for digital conversion of biosensor signal because of small process variation, and variable input range. As the input range of continuous-time switched current delta-sigma ADC (Dynamic range : 50 dB) can be limited by using current reference, amplification of biosensor signal is unnecessary. The input range is switched to wide input range mode or narrow input range mode by command of current reference. When the narrow input range mode, the input range becomes ± 0.8 V. The measured power consumption is 5 mW and chip area is 0.31 mm^2 using 1.2 um standard CMOS process. Additionally, automatic input range detecting system is proposed because of RFID biosensor applications.

Keywords: continuous time, delta sigma, A/D converter, RFID, biosensor, CMOS

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Authors: H. A. Alguhi, W. A. Elsaigh

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This paper provides a tensile stress-strain (σ-ε) relationship for High-Strength Steel Fiber Reinforced Concrete (HSFRC). Load-deflection (P-δ) behavior of HSFRC beams tested under four-point flexural load were used with inverse analysis to calculate the tensile σ-ε relationship for various tested concrete grades (70 and 90MPa) containing 60 kg/m³ (0.76 %) of hook-end steel fibers. A first estimate of the tensile (σ-ε) relationship is obtained using RILEM TC 162-TDF and other methods available in literature, frequently used for determining tensile σ-ε relationship of Normal-Strength Concrete (NSC) Non-Linear Finite Element Analysis (NLFEA) package ABAQUS^® is used to model the beam’s P-δ behavior. The results have shown that an element-size dependent tensile σ-ε relationship for HSFRC can be successfully generated and adopted for further analyses involving HSFRC structures.

Keywords: Tensile stress-strain, flexural response, high strength concrete, steel fibers, non-linear finite element analysis.

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Authors: Sky Chou, Joseph C. Chen

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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 C_p and C_pk 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: CNC machining, Six Sigma, Surface roughness, Taguchi methodology.

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