Discusses the Implementation of Six-Sigma Methodology - Management Assignment Help

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ABSTRACT

This paper discusses the implementation of Six-sigma methodology in reducing defectives in a cylinder liner manufacturing industry. The Six-sigma DMAIC (define– measure – analyze –improve – control) approach has been used to achieve this result. This paper explains the step-by-step approach of Six-sigma implementation in this manufacturing process for improving quality level. This resulted in reduction of rejection, and thus, reduced the Defect per Million Output (DPMO) from 66900 to 6050.This had resulted in increasing the sigma level from 2.91 to 4.43, without any huge capital investment. TPM is implemented which results in increase of Overall Equipment Efficiency (OEE). During this study, data is collected on all possible causes and was analyzed and thereby conclusions were made. Implementation of Six-sigma methodology and TPM has resulted in large financial savings for the firm.

KEYWORDS: Six-Sigma, DMAIC, Process Capability, Fishbone Diagram, SIPOC Diagram, Pareto Chart, Process Yield, Overall Equipment Efficiency (OEE), Total Productive Maintenance (TPM)

INTRODUCTION The fast changing economic conditions such as global competition, declining profit margin, customer demand for high quality product, product variety and reliable deliveries had a major impact on manufacturing industries. To respond to these needs various industrial engineering and quality management strategies such as Total Productive maintenance (TPM), Total Quality Management, Kaizen, JIT manufacturing,, Enterprise Resource Planning, Business Process Reengineering, Lean manufacturing have been developed. A new paradigm in this area of manufacturing strategies is Six Sigma. The Six Sigma approach has been increasingly adopted worldwide in the manufacturing sector in order to enhance productivity and quality performance and to make the process robust to quality variations. Six-sigma is a disciplined, systematic, data-driven approach to process improvement adopted by organizations world over. Motorola introduced the concept of six-sigma in the mid-1980s as a powerful business strategy to improve quality. Six-sigma continues to be the best-known approach for process improvement. Six Sigma is a business performance improvement strategy that aims to reduce the number of mistakes/defects to as low as 3.4 occasions per million opportunities. Sigma is a measure of “variation about the average” in a process which could be in manufacturing or service industry. Six Sigma improvement drive is the latest and most effective technique in the quality engineering and management spectrum. It enables organizations to make substantial improvements in their bottom line by designing and monitoring everyday business activities in ways which minimizes all types of wastes and Non Value Added (NVA) activities and maximizes customer satisfaction

CASE STUDY

A study was conducted in a firm which is a leading manufacturer o f cylinder liner for automotives. The firm i s accredited with ISO 9002 quality standards. The company has more than 200 employees. Major customers of the company in four wheeler segments are Ford, Telco, Fiat, Maruti, General Motors etc., and in two wheeler segments are Bajaj Auto, Kinetic Motors, LML, Yamaha, Hero Motors etc. As part of recent management change, the plant Six Sigma Implementation Using DMAIC Approach-A Case Study in a 13 Cylinder Liner Manufacturing Firm has initiated a company-wide quality improvement strategy. The firm’s principal product is a cast iron cylinder liner (or sleeve) that is inserted into the aluminum block produced by the engine manufacturer. Given the reliance of the liner company on this single class of products, it needs to respond quickly to the ever-increasing expectations of the customer. In fact, word has it, that the engine manufacturer soon plans to announce new, more stringent specifications for the liner. The firm has a vision to implement concepts of Six sigma, TPM, TQM, Kaizen, JIT, Lean manufacturing to achieve quality excellence. Given this background, an attempt is made to implement six sigma concept for process improvement.

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