Productivity Improvement of a Special Purpose Machine Using DMAIC Principles: A Case Study

Dambhare, Sunil; Aphale, Siddhant S.; Kakade, Kiran; Thote, Tejas; Borade, Atul B.

doi:10.1155/2013/752164

Cited by 6 publications

(2 citation statements)

References 22 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Bill Smith started the journey of Six Sigma process at Motorola Corporation, which lead them to won Malcolm Baldridge national award, Antony et al (2012), Dambhare et al (2013), Shanmugaraja et al (2011), Arnheiter and Maleyeff (2005). Afterwards, many multinational giant firms – allied signals, general electric, ABB – have implemented the concept of Six Sigma successfully (Andersson et al, 2006; Goh, 2002).…”

Section: Literature Surveymentioning

confidence: 99%

Competitive advantage through Six Sigma in sand casting industry to improve overall first-pass yield: a case study of SSE

Solanki¹,

Desai²

2020

IJLSS

View full text Add to dashboard Cite

Purpose The purpose of this paper is to illustrate how Six Sigma methodology has been applied in a small-scale foundry industry to improve the overall first-pass material yield and quality, with a view to the product and the process. Design/methodology/approach The researchers have reported this paper based on a case study carried out in industry using the Six Sigma Define, Measure, Analyze, Improve and Control (DMAIC) and its application in improving the manufacturing process of a foundry shop. Findings Identified root causes are validated and countermeasures are implemented for improvement. As a result of this case study, the overall first-pass yield of the sand casting process is improved to 78.88% from the previous yield of 67%. For product-specific case, yield is improved by 18% through the improved gating system design. Sigma level of the process is improved to 3.08 from baseline 2.21. Key lessons learned from this case study are mentioned in the current study. Research limitations/implications This case study provides a standard road map and motivates small-scale foundry industries to implement Six Sigma methodology for productivity improvement, especially in jobbing foundry. The presented paper is based on a single case study, and the results are limited to the company only. Also, one of the reasons for low process yield is slag creation, which is not covered here, as it is a concern of the material quality supplied by the vendor. However, the approach of this paper is generic for learning perspective. Practical implications This case study provides a standard road map and motivates small-scale foundry industries to implement Six Sigma methodology for productivity improvement, especially in jobbing foundry. Through the effective application of Six Sigma quality initiative, how a quantum jump in financial aspect could be gain, has been demonstrated. Originality/value This research study showcases step-by-step implementation of Six Sigma-DMAIC methodology at a small-scale foundry industry. This paper could serve as a unique roadmap for practitioners and academicians to improve the material productivity of the foundry industry both ways, product and process.

show abstract

Section: Literature Surveymentioning

confidence: 99%

Competitive advantage through Six Sigma in sand casting industry to improve overall first-pass yield: a case study of SSE

Solanki¹,

Desai²

2020

IJLSS

View full text Add to dashboard Cite

show abstract

“…DMAIC (define, measure, analyze, improve and control) is used to make improvement and to reduce defect products (Dambhare et al, 2013). By using Pareto Chart analysis we can define the highest cause of rejection.…”

Section: Literature Reviewmentioning

confidence: 99%

Reducing the nonconforming products by using the Six Sigma method: A case study of a polyes-ter short cut fiber manufacturing in Indonesia

Syafwiratama¹,

Hamsal²,

Purba³

2017

10.5267/j.msl

View full text Add to dashboard Cite

Polyester short cut fiber is a textile industry which is rarely explored or researched. This research explains the necessary steps of improvement using Six Sigma method to reduce the nonconforming products in a polyester short cut fiber manufacturing in Indonesia. An increased nonconforming products in the shortcut fiber production process created some quality problems from January to May, 2015. Define, measure, analysis, improve, control (DMAIC) steps were implemented to determine root cause of the problems and to improve production process using statistical approach. The results of Six Sigma improvement has indicated that the process capability was increased from 2.2 to 3.1 sigma, savings $18,394.2 USD per-month.

show abstract

Deep generative model with time series-image encoding for manufacturing fault detection in die casting process

Song

Lee

2022

J Intell Manuf

View full text Add to dashboard Cite

Productivity Improvement of a Special Purpose Machine Using DMAIC Principles: A Case Study

Cited by 6 publications

References 22 publications

Competitive advantage through Six Sigma in sand casting industry to improve overall first-pass yield: a case study of SSE

Competitive advantage through Six Sigma in sand casting industry to improve overall first-pass yield: a case study of SSE

Reducing the nonconforming products by using the Six Sigma method: A case study of a polyes-ter short cut fiber manufacturing in Indonesia

Deep generative model with time series-image encoding for manufacturing fault detection in die casting process

Contact Info

Product

Resources

About