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

Quality Improvement of Foundry Operation in Nigeria Using Six Sigma Technique

In this paper Six Sigma DMAIC analysis was applied in an aluminium mill in order to identify sources and causes of waste with the intention of providing veritable solutions. The foundry section was the segment under scrutiny. Re-work or defects in this firm was found to be on the average of about 37.05% of total production for the twenty-three months under study (January 2009- December 2010). Defect reduction was therefore chosen as the Critical-to-Quality (CTQ) factor. The sigma level of 1.87 in the firm indicated the existence of opportunities for improvement. Analysis was carried out using SPSS, SPC for Excel to perform regression analysis, process capability analysis, generate descriptive statistics, histograms and run charts. The results of these analyses identified three major defects and some of their behaviours. Based on the analysis, solutions were proffered in the Improve and Control phases of this project. Implementation of the proffered solutions resulted in noticeable improvement and led to the firm operating with near- perfect processes thus proving the applicability of Six Sigma

Port Sustainability Management System for Smaller Ports in Cornwall and Devon

Many smaller ports in Cornwall and Devon (CAD) are situated in environmentally sensitive habitats and generate benefits for stakeholders and local communities. Such ports are often embedded in tourist based economies. Increasing environmental legislation is placing a strain on the resources of smaller ports making compliance a threat to profitability and thus the future of some ports and local economies. Over-reliance on environmental management systems (EMS) across the ports industry has predominated over the importance of holistic sustainability. This project develops and disseminates a port sustainability management system (PSMS) in CAD, assisting ports to plan marine and maritime operations more sustainably, to facilitate mitigation of potential risks, to increase knowledge and awareness of port sustainability, and to promote the adoption of a proactive stance towards sustainable port management. A constructivist philosophy suited a multiple methods research design which included ethnographic content analysis (ECA), statistical verification of qualitative coding, nine scoping interviews, and eight semi-structured interviews during the main phase of data collection. The seven Harbour Masters (HMs) in this phase represented all port governance types found in the UK. Charmaz’s grounded theory (GT) methodology guided the collection and analysis of primary data between August 2012 and February 2013 to create new theory using an inductive constructivist approach. Validation by fifteen of the thirty local HMs during industry testing revealed numerous advantages and benefits of deploying PSMS which is estimated to generate £50,000 worth of benefits per port annually, and £3,865,005 for the 15 participating ports over 5 years. A new model of smaller port sustainability has emerged. PSMS has eleven pillars of sustainability which underpin the spectrum of port operations. Within this model, each pillar is equally important in contributing to the overall sustainability of a port, and neglect of one could jeopardise sustainability overall and potentially cause a chain reaction with other pillars.European Social Fund Combined Universities of Cornwall (ESF-CUC

Analytical Quality Control in Shipping Operation Using Six Sigma Principles

A large number of benefits achieved through the successful implementation of Six Sigma programmes in different industries have been documented. However, very little research has been conducted on their applications in the shipping sector, especially in the Onshore Service Functions (OSFs) of shipping companies. Literature shows that heavy human involvement in the service industries such as shipping leads to a high volume of uncertainties which are difficult to be correctly and effectively measured or managed by simply using the traditional data analysis and statistical methods in Six Sigma. The aim of this study is to develop new quantitative analytical methodologies to enable the application and implementation of Six Sigma to improve the service quality of OSFs in shipping companies. Intensive investigations on the feasibility and effectiveness of the developed new methods and models through case studies in world leading container ship lines and shipping management companies have been carried out to ensure the achievement of the aim.This study firstly reviews the evolvement of quality control and some typical methods in the area, the development of Six Sigma, its tools and current applications, especially in the service industries. It is followed by a new framework of the Six Sigma implementation in the OSFs of shipping companies which is supported by a few real process excellence projects carried out in a world-leading ship line. In the process of the framework development, various issues and challenges appear largely due to the existence of uncertainties in data such as ambiguity and incompleteness caused by extensive subjective judgements. Advanced methods and models are developed to tackle the above challenges as well as complement the traditional Six Sigma tools so that the new Six Sigma methodologies can be confidently applied in situations where uncertainties in data exist at different levels.A new fuzzy Technique for Order Preference by Similarity to an Ideal Solution ii(TOPSIS) method is developed by combining the traditional TOPSIS, fuzzy numbers and interval approximation sets to facilitate the effective selection of Six Sigma projects and achieve the optimal use of resources towards the company objectives. A revised Failure Mode and Effects Analysis (FMEA) model is proposed in the “Analyse” step in Six Sigma to improve the capability of classical FMEA in failure identification in service industries. The new FMEA model uses the Analytical Hierarchy Process (AHP) and Fuzzy Bayesian Reasoning (FBR) approaches to increase the accuracy of failure identification while not compromising the easiness and visibility of the Risk Priority Number (RPN) method. Decision Making Trial and Evaluation Laboratory (DEMATEL) and Analytical Network Process (ANP) methods are incorporated with Fuzzy logic and Evidential Reasoning (ER), for the very first time to generate a Key Performance Indicators (KPIs) management method where the weights of indicators are rationally assigned by considering the interdependency among the indicators. Incomplete and fuzzy evaluations of the KPIs are synthesised in a rational way to achieve a compatible and comparable result.It is concluded that the newly developed Six Sigma framework together with its supporting quantitative analytical models has made significant contribution to facilitate the quality control and process improvement in shipping companies. It has been strongly evidenced by the success of the applications of the new models in real cases. The financial gains and continuous benefits produced in the investigated shipping companies have attracted a wider range of interests from different service industries. It is therefore believed that this work will have a high potential to be tailored for a wide range of applications across sectors and industries when the uncertainties in data exceed the ability that the classical Six Sigma tools and methods possess