Reducing the delivery lead time in a food distribution SME through the implementation of six sigma methodology

Purpose – Six sigma is a systematic data driven approach to reduce the defect and improve the quality in any type of business. The purpose of this paper is to present the findings from the application of six sigma in a food service “small to medium sized enterprise” (SME) in a lean environment to reduce the waste in this field. Design/methodology/approach – A simplified version of six sigma is adopted through the application of appropriate statistical tools in order to focus on customer's requirements to identify the defect, the cause of the defect and improve the delivery process by implementing the optimum solution. Findings – The result suggests that modification in layout utilization reduced the number of causes of defect by 40 percent resulting in jumping from 1.44 sigma level to 2.09 Sigma level which is substantial improvement in SME. Research limitations/implications – Simplicity of six sigma is important to enabling any SME to identify the problem and minimize its cause through a systematic approach. Practical implications – Integrating of supply chain objectives with any quality initiatives such as lean and six sigma has a substantial effect on achieving to the targets. Originality/value – This paper represents a potential area in which six sigma methodology along side the lean management can promote supply chain management objectives for a food distribution SME

Application of six sigma methodology to reduce defects of a grinding process

Six Sigma is a data-driven leadership approach using specific tools and methodologies that lead to fact-based decision making. This paper deals with the application of the Six Sigma methodology in reducing defects in a fine grinding process of an automotive company in India. The DMAIC (Define–Measure–Analyse–Improve–Control) approach has been followed here to solve the underlying problem of reducing process variation and improving the process yield. This paper explores how a manufacturing process can use a systematic methodology to move towards world-class quality level. The application of the Six Sigma methodology resulted in reduction of defects in the fine grinding process from 16.6 to 1.19%. The DMAIC methodology has had a significant financial impact on the profitability of the company in terms of reduction in scrap cost, man-hour saving on rework and increased output. A saving of approximately US$2.4 million per annum was reported from this project

Towards Structural Testing of Superconductor Electronics

Many of the semiconductor technologies are already\ud facing limitations while new-generation data and\ud telecommunication systems are implemented. Although in\ud its infancy, superconductor electronics (SCE) is capable of\ud handling some of these high-end tasks. We have started a\ud defect-oriented test methodology for SCE, so that reliable\ud systems can be implemented in this technology. In this\ud paper, the details of the study on the Rapid Single-Flux\ud Quantum (RSFQ) process are presented. We present\ud common defects in the SCE processes and corresponding\ud test methodologies to detect them. The (measurement)\ud results prove that we are able to detect possible random\ud defects for statistical purposes in yield analysis. This\ud paper also presents possible test methodologies for RSFQ\ud circuits based on defect oriented testing (DOT)

Using the ISO/IEC 9126 product quality model to classify defects : a Controlled Experiment

Background: Existing software defect classification schemes support multiple tasks, such as root cause analysis and process improvement guidance. However, existing schemes do not assist in assigning defects to a broad range of high level software goals, such as software quality characteristics like functionality, maintainability, and usability. Aim: We investigate whether a classification based on the ISO/IEC 9126 software product quality model is reliable and useful to link defects to quality aspects impacted. Method: Six different subjects, divided in two groups with respect to their expertise, classified 78 defects from an industrial web application using the ISO/IEC 9126 quality main characteristics and sub-characteristics, and a set of proposed extended guidelines. Results: The ISO/IEC 9126 model is reasonably reliable when used to classify defects, even using incomplete defect reports. Reliability and variability is better for the six high level main characteristics of the model than for the 22 sub- characteristics. Conclusions: The ISO/IEC 9126 software quality model provides a solid foundation for defect classification. We also recommend, based on the follow up qualitative analysis performed, to use more complete defect reports and tailor the quality model to the context of us

Supplier development practice: arising the problems of upstream delivery for a food distribution SME in the UK

The paper aims to emphasize on the impacts of the supplier development on reducing the defects in supplier quality for a food distribution small–medium sized enterprise (SME). An empirical study was conducted to measure the performance of the suppliers in three different key performance indicators of the outsourcing and supplier’s performance to arise the existing problems via information exchange, data collection and data analysis. It was found that supplier development through data and information exchange and better communication by any food distribution SME raises the problems more promptly. This can dramatically change the supplier’s behavior to improve the quality of the supplier’s service and products. It is suggested that more research is required to raise other key performance indicators and their related problems and to develop more improvement practices. Six sigma methodologies could be the potential good practices to be focused in future research studies. Supplier performance measurement, which encompasses data exchange and data collection, develops the systematic flow of information, which potentially improves the flow of goods and the whole food supply chain to address the final consumer satisfaction. The research took a novel approach in adopting some transport related key performance indicators of the food supply to the food distribution and retailing sector, which is almost a new approach in food industry

Implementing the Lean Sigma Framework in an Indian SME: a case study

Lean and Six Sigma are two widely acknowledged business process improvement strategies available to organisations today for achieving dramatic results in cost, quality and time by focusing on process performance. Lately, Lean and Six Sigma practitioners are integrating the two strategies into a more powerful and effective hybrid, addressing many of the weaknesses and retaining most of the strengths of each strategy. Lean Sigma combines the variability reduction tools and techniques from Six Sigma with the waste and non-value added elimination tools and techniques from Lean Manufacturing, to generate savings to the bottom-line of an organisation. This paper proposes a Lean Sigma framework to reduce the defect occurring in the final product (automobile accessories) manufactured by a die-casting process. The proposed framework integrates Lean tools (current state map, 5S System, and Total Productive Maintenance (TPM)) within Six Sigma DMAIC methodology to enhance the bottom-line results and win customer loyalty. Implementation of the proposed framework shows dramatic improvement in the key metrics (defect per unit (DPU), process capability index, mean and standard deviation of casting density, yield, and overall equipment effectiveness (OEE)) and a substantial financial savings is generated by the organisation

A Preliminary Study of Applying Lean Six Sigma Methods to Machine Tool Measurement

Many manufacturers aim to increase their levels of high-quality production in order to improve their market competitiveness. Continuous improvement of maintenance strategies is a key factor to be capable of delivering high quality products and services on-time with minimal operating costs. However, the cost of maintaining quality is often perceived as a non-added-value task. Improving the efficiency and effectiveness of the measurement procedures necessary to guarantee accuracy of production is a more complex task than many other maintenance functions and so deserves particular analysis. This paper investigates the feasibility of producing a concise yet effective framework that will provide a preliminary approach for integrating Lean and Six Sigma philosophies to the specific goal of reducing unnecessary downtime on manufacturing machines while maintaining its ability to machine to the required tolerance. The purpose of this study is to show how a Six Sigma infrastructure is used to investigate the root causes of complication occurring during the machine tool measurement. This work recognises issues of the uncertainty of data, and the measurement procedures in parallel with the main tools of Six Sigma’s Define-Measure-Analyse-Improve-Control (DMAIC). The significance of this work is that machine tool accuracy is critical for high value manufacturing. Over-measuring the machine to ensure accuracy potentially reduces production volume. However, not measuring them or ignoring accuracy aspects possibly lead to production waste. This piece of work aims to present a lean guidance to lessen measurement uncertainties and optimise the machine tool benchmarking procedures, while adopting the DMAIC strategy to reduce unnecessary downtime