PurposeBy exploiting the relationships between Six Sigma and quality management systems (QMS) based on the ISO 9001 standard, this paper proposes a set of guidelines to combine and integrate both approaches in a systematic way. The guidelines are organised into integration topics, and each one is linked to the clauses of the ISO 9001 standard they refer to.Design/methodology/approachBased on the literature review, Six Sigma and QMS based on the ISO 9001 standard are thoroughly discussed and compared and beneficial synergies between them are identified. Based on this study, and to take advantage of the compatibilities and logical linkages between both approaches, guidelines for the integration of Six Sigma with the ISO 9001 requirements are developed.FindingsBenefits resulting from the integration of Six Sigma with a QMS based on the ISO 9001 standard are mutual. The integration guidelines proposed in this paper provide a framework to unify process management practices, enhance the effectiveness of continual improvement efforts, facilitate the identification, evaluation and selection of Six Sigma projects, align the quality objectives defined for the QMS with Six Sigma project goals, establish relationships between the roles of a Six Sigma program and those inherent to an ISO 9001 QMS, and demonstrate how internal quality audits and management review benefit from a Six Sigma program.Research limitations/implicationsThe integration models and guidelines herein proposed can be further expanded to include other relevant normative references, particularly environmental management systems (ISO 14001) and safety and health management systems (OHSAS 18001).Originality/valueThe set of guidelines proposed in this paper is original and will be of practical value to the increasing number of organisations adopting a process‐model for the ISO 9001 standard, that seek to incorporate Six Sigma principles, practices, methods and tools within their QMS. The guidelines cover a wide spectrum of relevant activities that usually take place in the context of both initiatives. In addition, because each guideline is accompanied by the identification of the applicable clauses of ISO 9001, they provide a useful framework to develop, implement, maintain, and improve a QMS in parallel with a Six Sigma program.

Purpose The purpose of this paper is to illustrate an application of the Six Sigma define, measure, analyze, improve, control (DMAIC) problem-solving methodology in a Portuguese industrial enterprise, aimed at reducing the rejection rate of a specific manufactured product due to defects generated in an aluminum gravity die casting operation. Design/methodology/approach Along the five-stage roadmap, a set of analytical and conceptual tools was systematically employed to better characterize the problem, define the product’s critical to quality characteristics, estimate the process baseline, determine the relevant cause-and-effect relationships, identify the root causes leading to the high rejection rate, implement an improvement plan, determine the effectiveness of the improvement actions, and put in place a control plan. Findings The project team discovered that the high rejection rate was caused by factors inherent to the gravity die casting operation itself and by the mixing of rejected parts made of different types of alloys from other locations within the plant. Another key finding was that the successful execution of the project was only possible due to the belief and support of top management and to the active involvement of the team members. Practical implications This case study illustrates a successful practical application of a Six Sigma project in a small-medium enterprise in Portugal, as well as the operational and financial benefits that derived from it; thus providing a good example for others to follow. Originality/value Few cases of continual improvement initiatives, including Six Sigma projects, developed at a Portuguese company are available in the literature; this paper fills such void by describing a very successful application that demonstrates the advantages that other companies can learn in terms of adopting structured methodologies to improve the quality of their products and the efficiency of their processes. Moreover, the analysis and conclusions herein presented can be of great importance for companies using gravity die casting technology.

No abstract

Abstract-Nowadays, customers are increasingly claiming not only for better quality products at the lowest possible cost, but also demanding customized solutions to satisfy their specific, sometimes unique, needs and wants. Due to this, manufacturing companies are seeking to adopt higher agile production models, such as mass customization strategies. In the quality control field, statistical process control (SPC) methods have been widely used to monitor process performance and detect abnormal situations in its behavior; however, traditional SPC approaches are usually not appropriate for small lot or batch sizes, for the start-up of a process, and for situations where a high variety of mixed products exist. Such situations are within the scope of the so called short production runs. Several SPC schemes have been proposed for short-run environments; all of them have their own advantages, shortcomings, and more suitable for certain production scenarios. This paper provides an up-to-date literature review on the topic, identifies classes of SPC short-run methods, and presents a decision-model that guides production managers in the choice of the most appropriate SPC short-run approach. The model was validated in a textile production company, and is being incorporated into a software package.Index Terms-Decision-model, short-run, statistical process control (SPC).

This paper presents a real application of a lean–green improvement initiative conducted at a large Portuguese hypermarket store. It explores how lean tools and techniques may be used to not only improve the operational performance, but also sustainability. A case study was carried out in one store of a multinational retail enterprise, with the aim of enhancing both the operational and sustainability performance in the cold meat section, one of the most relevant areas of the fresh food markets. The Gemba Kaizen event approach, which comprises three main stages, was adopted. During the workshop stage, the structured problem-solving methodology was followed, and was recorded in an A3 format. As a consequence of this project, food waste in the cold meat market was reduced by half, whereas the out-of-stock index decreased by a third. In addition, the pilot store hit top performance within all stores of the company in Portugal, ranking first in all key indicators for the cold meat market. The lean–green scope and performance improvement procedures developed and implemented in the pilot store were later deployed to other stores of the company. This is one of the first publications regarding the application of lean management in the food retail sector for improving both the operational and sustainability performance.