Application of Six Sigma DMAIC methodology in plain yogurt production process

Hakimi, Saeid; Zahraee, Seyed Mojib; Rohani, Jafri Mohd

doi:10.1108/ijlss-11-2016-0069

Cited by 50 publications

(41 citation statements)

References 41 publications

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“…The company advantage in applying this method can reduce costs tremendously [18]. This method is still developing in increasing productivity in the food and beverage industry [19], [20] and optimizing the production process in the textile industry [21]. The Six Sigma DMAIC method focuses on reducing process variability to produce high-quality products and creating an efficient process obtained without waste, resulting in added value for customers [22].…”

Section: Fig 1 Roof Panel Partmentioning

confidence: 99%

Defect reduction of roof panel part in the export delivery process using the DMAIC method: a case study

Setiawan¹,

Setiawan²

2020

j. sist. manaj. ind.

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Product quality has now become one of the main factors that every company must have to compete globally. One way is to reduce the number of defective products in the production process. This method is a continuous improvement effort made by PT Toyota Motor Manufacturing Indonesia and companies engaged in the automotive sector that produces cars. One of the processes is packing roof panels whose output will be sent to importing countries where the number of requests per month is relatively high but still has a high defect rate. Based on production data and defect data for the January-February 2019 period, roof panel packaging production has a 1% -3% defect rate. This company must reduce the defect rate to achieve the company target of zero defects. This study aims to improve the quality of the packaging process by minimizing the number of defective products. This study uses the Six Sigma method with DMAIC phases. This method has several phases, namely, Define, Measure, Analysis, Improvement, and Control. Corrective action to reduce product defects based on 5W + 1H is to formulate a repair plan at the upgrade phase, namely by making SOPs spraying anti-rust and supervising operators who produce roof panel packaging. The improvement results reduced the DPMO value from 33,500 units to 2,050 units and increased the sigma level from 3.33 to 4.37. The DMAIC phase effectively controls and improves product quality levels in the automotive industry.

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Section: Fig 1 Roof Panel Partmentioning

confidence: 99%

Defect reduction of roof panel part in the export delivery process using the DMAIC method: a case study

Setiawan¹,

Setiawan²

2020

j. sist. manaj. ind.

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“…There are several factors which could potentially influence the quality of cast lead sheets and promote the formation of grooves. Hence, based on process observation, literature review [12,22,23] and the experience of foundry engineers, all the possible factors affecting the quality of sheets were categorised based on a 5 M model (Man, Material (Melt), Machine (Mould), Method, Measurement) and environment [24] (see Table 2). There are several factors which could potentially influence the quality of cast lead sheets and promote the formation of grooves.…”

Section: Defect Analysismentioning

confidence: 99%

Minimising Defect Formation in Sand Casting of Sheet Lead: A DoE Approach

Prabhakar

Papanikolaou

Salonitis

et al. 2020

Metals

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Sand casting of lead sheet is a traditional manufacturing process used up to the present due to the special features of sand cast sheet such as their attractive sheen. Similarly to any casting process, sand casting of lead sheet suffers from the presence of surface defects. In this study, a surface defect type, hereby referred to as ‘grooves’, has been investigated. The focus has been laid on the identification of the main factors affecting defect formation in this process. Based on a set of screening experiments performed using Scanning Electron Microscopy (SEM) as well as the existing literature, a number of factors affecting the formation of such defects was identified and their corresponding significance was estimated using the Analysis of Variance (ANOVA) technique. The obtained results suggest that the most significant factor affecting defect formation in sand casting of lead sheet is the composition of the moulding mixture. Defect formation was also proven to be dependent on the sand grain fineness, the quality of the melt and some of the interactions between the aforementioned process parameters. Finally, an optimal set of process parameters leading to the minimisation of surface defects was identified.

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“…Previous research that used the SS method/approach showed that it was a significant method to decrease defects (Hakimi et al, 2018). This method is still developing to reduce costs and increase productivity in the food industry (Costa et al, 2018).…”

Section: Introductionmentioning

confidence: 99%

Halal six sigma framework for defects reduction

Vanany

Tan

Siswanto

et al. 2020

JIMA

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Purpose In recent years, halal food industries are facing a high level of competition. The growing demand for halal food means firms are working hard to improve quality and reduce halal food defects. The purpose of this study is to propose a halal-based six sigma (SS) framework that could be used to reduce halal food defects and improve compliance. Design/methodology/approach The proposed halal six sigma (HSS) framework has five phases based on the define-measure-analyse-improve-control (DMAIC) approach. The proposed framework also integrates halal assurance system requirements into HSS to ensure compliance. Tools used in the proposed model include SIPOC tools, Pareto diagram, root cause analysis and the improvement process flows. A case study in a chicken meat company is used to test and validate the proposed framework. In case of study research, brainstorming was used to review an initial proposed framework and focus group discussions were used to determine feasible improvement actions. Findings The results showed that the proposed HSS framework could be effective to detect and reduce the halal defects and lower the halal defect costs. By adopting the framework, the case firm was able to lower halal defect costs significantly and increase the SS level. Practical implications SS approach can be designed and adapted to specific food industry. HSS framework could provide a systematic approach to reduce halal food defects and sustain the improvement efforts. The proposed HSS framework is also easy to use to understand halal critical points and improve halal compliance. Originality/value This study proposed a HSS framework that can be adopted to reduce halal food defects and costs. This proposed framework will benefit the halal food industry intending to realize zero halal food defects and lower production costs. The limited number of publications in the research theme of halal food defects show that there is a significant gap in the existing body of knowledge.

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Application of Six Sigma DMAIC methodology in plain yogurt production process

Cited by 50 publications

References 41 publications

Defect reduction of roof panel part in the export delivery process using the DMAIC method: a case study

Defect reduction of roof panel part in the export delivery process using the DMAIC method: a case study

Minimising Defect Formation in Sand Casting of Sheet Lead: A DoE Approach

Halal six sigma framework for defects reduction

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