Case study in six sigma methadology : manufacturing quality improvement and guidence for managers

This article discusses the successful implementation of Six Sigma methodology in a high precision and critical process in the manufacture of automotive products. The Six Sigma define–measure–analyse–improve–control approach resulted in a reduction of tolerance-related problems and improved the first pass yield from 85% to 99.4%. Data were collected on all possible causes and regression analysis, hypothesis testing, Taguchi methods, classification and regression tree, etc. were used to analyse the data and draw conclusions. Implementation of Six Sigma methodology had a significant financial impact on the profitability of the company. An approximate saving of US$70,000 per annum was reported, which is in addition to the customer-facing benefits of improved quality on returns and sales. The project also had the benefit of allowing the company to learn useful messages that will guide future Six Sigma activities

Photovoltaic system criteria documents. Volume 2: Quality assurance criteria for photovoltaic applications

Quality assurance criteria are described for manufacturers and installers of solar photovoltaic tests and applications. Quality oriented activities are outlined to be pursued by the contractor/subcontractor to assure the physical and operational quality of equipment produced is included. In the broad sense, guidelines are provided for establishing a QA organization if none exists. Mainly, criteria is provided to be considered in any PV quality assurance plan selected as appropriate by the responsible Field Center. A framework is established for a systematic approach to ensure that photovoltaic tests and applications are constructed in a timely and cost effective manner

An application of Six Sigma to reduce waste

Six Sigma has been considered a powerful business strategy that employs a well-structured continuous improvement methodology to reduce process variability and drive out waste within the business processes using effective application of statistical tools and techniques. Although there is a wider acceptance of Six Sigma in many organizations today, there appears to be virtually no in-depth case study of Six Sigma in the existing literature. This involves how the Six Sigma methodology has been used, how Six Sigma tools and techniques have been applied and how the benefits have been generated. This paper presents a case study illustrating the effective use of Six Sigma to reduce waste in a coating process. It describes in detail how the project was selected and how the Six Sigma methodology was applied. It also shows how various tools and techniques within the Six Sigma methodology have been employed to achieve substantial financial benefits

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

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

Driving continuous improvement

The quality of improvement depends on the quality of leading and lagging performance indicators. For this reason, several tools, such as process mapping, cause and effect analysis and FMEA, need to be used in an integrated way with performance measurement models, such as balanced scorecard, integrated performance measurement system, performance prism and so on. However, in our experience, this alone is not quite enough due to the amount of effort required to monitor performance indicators at operational levels. The authors find that IT support is key to the successful implementation of performance measurement-driven continuous improvement schemes

Skyport airframe: design and manufacturing

Many rural areas of developing countries lack the necessary transportation infrastructure to have reliable access to basic needs. This is particularly true for medical supplies. To combat the issue of insufficient access to vaccines in developing areas, the SkyPort project has developed the SkyPort UAV (Unmanned Aerial Vehicle). The SkyPort UAV has the vertical takeoff and landing (VTOL) capabilities of a quadcopter, as well as the efficient, sustained flight of a fixed-wing aircraft. It provides a cheaper, quicker, and safer delivery method than existing alternatives for vaccines in areas that lack a reliable transportation infrastructure. The role of the SkyPort Airframe Design Team was to design and build the primary support structure of the UAV, which will house the payload, controls, and propulsion systems being designed by the other two SkyPort teams. The airframe consists of a lightweight and durable fuselage, wing, tail, and framing subsystems and it is designed to be modular so that parts are easy to replace and require minimal maintenance. Primary materials used in construction were foam, carbon fiber, and aluminum. Testing of the frame yielded a weight of 8.63 kg, minimum foam strength of 1.70 MPa, and a minimum factor of safety of 16 for the structural members of the frame. Although the weight of the airframe is higher than the desired weight, this was necessary in order to satisfy the strength requirements and protect sensitive electrical components during initial flight tests. In the future, this extra weight could be decreased by using less carbon fiber, lower density foam, smaller, lighter material for the structural members, or smaller fasteners

Shainin methodology: An alternative or an effective complement to Six Sigma?

Purpose: The purpose of this paper is to provide a brief overview of Six Sigma and Shainin RedX (R) methodology and to propose the modification of Six Sigma methodology in order to achieve the improved efficiency of DMAIC in the diagnostic journey using some of the approaches of Shainin RedX (R) methodology. Methodology/Approach: The diagnostic journey of Six Sigma has been revised by bringing key elements of Shainin RedX (R) methodology into DMAIC: task domain character of the method, focus on the dominant root-cause, use of the progressive elimination method and the application of a problem-solving strategy. Findings: This paper presents a proposal of DMAIC framework modification using selected tools and procedures of Shainin RedX (R) methodology in the diagnostic phase. Research Limitation/implication: Although the improved methodology is used in the environment of the automotive supplier, in this paper, practical examples are not included in order not to violate the licensing rules applied by Shainin LLC. Originality/Value of paper: The contribution of this article is the proposal of modified methodology, which should improve the effectiveness of problem-solving.Web of Science192311

Clinical implications of the anisotropic analytical algorithm for IMRT treatment planning and verification

PURPOSE: To determine the implications of the use of the Anisotropic Analytical Algorithm(AAA) for the production and dosimetric verification of IMRT plans for treatments of the prostate, parotid, nasopharynx and lung. METHODS: 72 IMRT treatment plans produced using the Pencil Beam Convolution (PBC)algorithm were recalculated using the AAA and the dose distributions compared. 24 of the plans were delivered to inhomogeneous phantoms and verification measurements made using a pinpoint ionisation chamber. The agreement between the AAA and measurement was determined. RESULTS: Small differences were seen in the prostate plans, with the AAA predicting slightly lower minimum PTV doses. In the parotid plans, there were small increases in the lens and contralateral parotid doses while the nasopharyngeal plans revealed a reduction in the volume of the PTV covered by the 95% isodose (the V95%) when the AAA was used. Large changes were seen in the lung plans, the AAA predicting reductions in the minimum PTV dose and large reductions in the V95%. The AAA also predicted small increases in the mean dose to the normal lung and the V20. In the verification measurements, all AAA calculations were within 3% or 3.5mm distance to agreement of the measured doses. Conclusions: The AAA should be used in preference to the PBC algorithm for treatments involving low density tissue but this may necessitate re-evaluation of plan acceptability criteria. Improvements to the Multi-Resolution Dose Calculation algorithm used in the inverse planning are required to reduce the convergence error in the presence of lung tissue. There was excellent agreement between the AAA and verification measurements for all sites

Winning customer loyalty in an automotive company through Six Sigma: a case study

Six Sigma is a disciplined approach to improving product, process and service quality. Since its inception at Motorola in the mid 1980s Six Sigma has evolved significantly and continues to expand to improve process performance, enhance business profitability and increase customer satisfaction. This paper presents an extensive literature review based on the experiences of both academics and practitioners on Six Sigma, followed by the application of the Define, Measure, Analyse, Improve, Control (DMAIC) problem-solving methodology to identify the parameters causing casting defects and to control these parameters. The results of the study are based on the application of tools and techniques in the DMAIC methodology, i.e. Pareto Analysis, Measurement System Analysis, Regression Analysis and Design of Experiment. The results of the study show that the application of the Six Sigma methodology reduced casting defects and increased the process capability of the process from 0.49 to 1.28. The application of DMAIC has resulted in a significant financial impact (over U.S. $110 000 per annum) on the bottom-line of the company