Development and validation of DMAIC based framework for process improvement: a case study of Indian manufacturing organization

Kumar, Pramod; Singh, Dharmendra; Bhamu, Jaiprakash

doi:10.1108/ijqrm-10-2020-0332

Cited by 13 publications

(15 citation statements)

References 43 publications

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“…In addition, the effectiveness and efficiency of these solutions must be proven and implemented; and, (5) Control: the decision team sets some standards and provides feedback to support improvements. LSS and DMAIC literature shows important case studies recently published, for instance: Araman and Saleh (2022) applied DMAIC methodology in an extrusion process; Kakaei-Lafdani et al (2022) described how to implement Six Sigma on the spiral welded pipe manufacturing; Panayiotou et al (2021) implemented LSS in a manufacturing small and medium-sized; Hardy et al (2021) applied LSS DMAIC in laminated panel production; Kumar et al (2021) developed a DMAIC based framework and a fasteners' manufacturer; Gijo et al (2018) applied the LSS methodology to achieve an expressive drilling defect reduction; Bhat et al (2020) applied action research methodology to study the competitiveness for micro, small and medium companies; Noronha et al (2021) implemented LSS strategy to improve healthcare performance.…”

Section: Defect Reduction In Car Parts Suppliermentioning

confidence: 99%

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Defect reduction using DMAIC and Lean Six Sigma: a case study in a manufacturing car parts supplier

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Pimenta

et al. 2023

IJQRM

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PurposeCompetitive pressures force companies to seek solutions to eliminate wastes while improving product quality. Lean Six Sigma (LSS) has been considered one of the most effective approaches for business transformation. This article aims to present an empirical case study where LSS and Define, Measure–Analyze–Improve–Control (DMAIC) methodologies are applied to reduce defects in a car parts manufacturer.Design/methodology/approachThe study follows the DMAIC methodology. Design of experiments and hypothesis testing were applied in a single case study.FindingsThe main defects and the main factors that cause defective parts were indicated for die-casting and machining processes. Solutions implemented reduced the defect incidence from a chronically high level to an acceptable one. The sigma level rose from 3.4 s to 4 s sustainably.Research limitations/implicationsThe study is limited to a single case study, without intention of generalizing the results to other types of industries.Practical implicationsThis paper can be a useful guide of how to use DMAIC Six Sigma approach to defect reduction and can be applied in many sectors.Social implicationsThis study offers the knowledge on how to apply the Six Sigma DMAIC methodology, reducing the dependence on specialization courses.Originality/valueThis study describes in detail the process used in a structured improvement exercise including sigma-level calculation, factorial experiments and hypothesis tests – a set of techniques still poorly combined in the literature.

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Section: Defect Reduction In Car Parts Suppliermentioning

confidence: 99%

“…(2021) implemented LSS in a manufacturing small and medium-sized; Hardy et al. (2021) applied LSS DMAIC in laminated panel production; Kumar et al. (2021) developed a DMAIC based framework and a fasteners' manufacturer; Gijo et al.…”

Section: Literature Reviewmentioning

confidence: 99%

Defect reduction using DMAIC and Lean Six Sigma: a case study in a manufacturing car parts supplier

Condé

Oprime

Pimenta

et al. 2023

IJQRM

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“…It was originally proposed by Motorola in 1986 [9,10]. In terms of the manufacturing process, the six sigma method combines the statistical analysis method of manufacturing cost and production data, enabling process engineers to define, measure, analyze, improve, and control, abbreviated as the DMAIC improvement process to enhance process and process quality [11][12][13]. After Motorola, American General Electric Company (GE)also began to promote this method vigorously in 1995, not only achieving remarkable results, but also doubling its operating performance.…”

Section: Introductionmentioning

confidence: 99%

Construct Six Sigma DMAIC Improvement Model for Manufacturing Process Quality of Multi-Characteristic Products

Huang

Chen

et al. 2022

Mathematics

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After a product has undergone a manufacturing process, it usually has several important quality characteristics. When the process quality of all quality characteristics meets the requirements of the quality level, the process quality of the product can be guaranteed to satisfy customers’ needs. A large number of studies have pointed out that good process quality can raise product yield and product value; at the same time, it can reduce the ratio of rework and scrap, achieve the effect of energy saving and waste reduction, and contribute to the sustainable operation of enterprises as well the environment. Since the six sigma method combines the statistical analysis method of manufacturing cost and production data, it is a useful tool for process improvement and process quality enhancement. Therefore, this paper adopted the six sigma-define, measure, analyze, improve and control (DMAIC) improvement process to lift the manufacturing process quality of multi-characteristic products. Besides, the Taguchi process capability index is one of the commonly used tools for quality assessment in the industry. Not only can it reflect the process loss, but it also can ensure the process yield when the index value is large enough. Consequently, this paper discussed the relationship between the Taguchi process capability index and the six sigma quality level. Meanwhile, the entire six sigma DMAIC improvement process was built on the basis of the process capability index and developed by the method of statistical quality control. Hence, the proposed method is very convenient for process engineers to apply, as well as is helpful for enterprises to move toward the goal of smart manufacturing and sustainability.

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“…The design of experiment (DOE) was used to identify the significant process parameters that contributed to product defects, and thus, the optimum setting required of key process parameters to solve the problem of product quality was determined. More recent examples of the application of DMAIC steps were presented by Khan et al (2020), Patyal et al (2021), Kumar et al (2021) and Hardy et al (2021). On the other hand, the DMADV steps were used to solve a problem related to design.…”

Section: Introductionmentioning

confidence: 99%

“…More recent examples of the application of DMAIC steps were presented by Khan et al (2020), Patyal et al (2021), Kumar et al (2021) and Hardy et al (2021). On the other hand, the DMADV steps were used to solve a problem related to design.…”

Section: Introductionmentioning

confidence: 99%

Integration of Six Sigma methodology of DMADV steps with QFD, DFMEA and TRIZ applications for image-based automated inspection system development: a case study

Purushothaman

Ahmad

2022

IJLSS

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Purpose This paper aims to present the development of an automated inspection system (AIS) using an image-based analysis mechanism, called i-AIS. The development process of i-AIS used the Design Six Sigma (DSS) methodology. The steps of define, measure, analyze, design and verify (DMADV) are applied and integrated with specific analyses techniques of the quality function deployment (QFD), design failure mode effect analysis (DFMEA) and theory of inventive problem solving (TRIZ). The production process of adhesive tape is the focused case study in this research project, motivated by the high product defect rate complained by customers. Design/methodology/approach The development process of i-AIS was divided into five standard steps based on the DSS methodologies of DMADV. One of the key processes in this development was to systematically identify the right and intended features of i-AIS. This was carried out based on the application of the QFD technique. Another important process was to further investigate the possible causes of i-AIS failure, to function as intended. This investigative process was carried out based on the DFMEA technique, while the solution to minimize the risk of the identified failures was obtained from the TRIZ method. The final prototype of i-AIS was then presented in the design step. Findings Verification of the i-AIS prototype revealed its operation at an optimally intended mode that fulfilled the requirements of internal customers. Verification results also revealed that the sigma level has improved from 3.87 to 4.33. Meanwhile, the defect reduction rate is improved to 74.4% and downtime rate also recorded a significant improvement at 80.7% of reduction. Research limitations/implications The presented research work is carried out based on a customized case study. Although the proposed methodology can be applied to others cases towards design-based solution, some modifications maybe required based on to the unique features of the case study under consideration. Practical implications The presented research project indicated that the proposed methodology was successful to facilitate a structured and systematic process towards defect identification, classification, evaluation and generation of a solution. Originality/value The paper presents the development process of an AIS by considering comprehensive managerial aspects that are currently absent in the literature. An integrated DSS structure is proposed to systematically guide the development of i-AIS. The related managerial aspects such as identification of critical defects problem, customer requirement mapping, prototype design analysis and comparison measurements before and after i-AIS installation are considered in this research project.

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Development and validation of DMAIC based framework for process improvement: a case study of Indian manufacturing organization

Cited by 13 publications

References 43 publications

Defect reduction using DMAIC and Lean Six Sigma: a case study in a manufacturing car parts supplier

Defect reduction using DMAIC and Lean Six Sigma: a case study in a manufacturing car parts supplier

Construct Six Sigma DMAIC Improvement Model for Manufacturing Process Quality of Multi-Characteristic Products

Integration of Six Sigma methodology of DMADV steps with QFD, DFMEA and TRIZ applications for image-based automated inspection system development: a case study

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