Waste reduction of polypropylene bag manufacturing process using Six Sigma DMAIC approach: A case study

Sajjad, Muhammad Hamad; Naeem, Khawar; Zubair, Muhammad; Jan, Qazi Muhammad Usman; Khattak, Sikandar Bilal; Omair, Muhammad; Nawaz, Rashid; Guo, Jun

doi:10.1080/23311916.2021.1896419

Cited by 14 publications

(7 citation statements)

References 38 publications

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“…According to a study by Sajjad et al [9], it was found that some organizations have applied the six sigma DMAIC process to effectively control the quality of their processes. Therefore, this research was conducted according to the six sigma DMAIC approach as follows.…”

Section: Experimental Designmentioning

confidence: 99%

An Application of Six Sigma for Optimality of Medium Density Fiberboard Production

Jitsamruay¹,

Chinram²,

Poolyarat³

et al. 2023

Int. J. Anal. Appl.

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During the production process of MDF, there is a high level of internal bond (IB) variation. This results in the waste of out-of-standard IB values that account for 0.38 % with damage value over 1 million baht/year. The company required products with fewer volatile compounds from formaldehyde adhesives, focusing on reducing the amount of adhesive but still being strong according to IB-specification which will reduce the cost of production by about 20 − 30 million baht/year. The results of wood sampling and IB testing were divided into 6 areas, namely IB1-IB6. It was found that most of the data were symmetrical except for the IB5 data as the area where the most variation occurs. The distributions of the IB1 and IB6 data showed relatively low variability compared to data from other areas. IB1 - IB6 values were normal distribution, expect for IB5. Process capacity in IB2 was relatively high compared to IB from other areas. From the Correlation Matrix and Correlation Map, it was found that the variables that influenced the IB were Press Factor, % Dosing Glue, Heat Circuit1, Primary Circuit Intel and % Mc After Gluing. To conduct the experiment and find the best variable conditions by 25-2 - Factorial Design (Resolution: III). It was found that Glue = 7.4, Heat1 = 234.4, and Press = 6.5 would give IB = 0.88 which was closest to target (0.7). Glue = 7.1, Heat1 = 233.2, and Press = 6.48 would give IB = 1.15 which was the highest value. Results of production conditions at optimum or maximum that can be generalized from Rayleigh Method Dimensional Analysis was found that at the levels of 7.85, 254.28 and 257.70 of Glue, Heat1 and PrimCirIn, the target response (IB) was 0.7. and at the levels of 8.07, 233.35 and 281.60 of Glue, Heat1 and PrimCirIn resulted in a response value (IB) of 1.27.

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Section: Experimental Designmentioning

confidence: 99%

An Application of Six Sigma for Optimality of Medium Density Fiberboard Production

Jitsamruay¹,

Chinram²,

Poolyarat³

et al. 2023

Int. J. Anal. Appl.

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“…lower nonconformity rate in the industry, increased performance and improved customer satisfaction (Kuvvetli et al , 2016). Sajjad et al (2021) attempted to decrease polypropylene bag waste rejection at the chosen production system by applied SS DMAIC approach. The SS DMAIC strategy focuses on connecting company and customer demands for the benefit of continuous improvement principles (Tampubolon and Purba, 2021).…”

Section: Literature Reviewsmentioning

confidence: 99%

Application of Six Sigma methodology using DMAIC approach for a packaging olives production system: a case study

Tsarouhas,

Sidiropoulou

2023

IJLSS

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Purpose In a packaging olives manufacturing system, the drained weight of the product plays a decisive role in customer’s satisfaction as well as in financial saving for the organization. The purpose of this study is to minimize the variation of the drained weight of olives in the production system to avoid the negative consequences. Design/methodology/approach The research develops a practical implementation step-by-step of Six Sigma define, measure, analyze, improve and control (DMAIC) in reducing the variation of the drained weight of olives. Findings Data analysis was used at various phases of the project to identify the root causes of rejection and rework. As a result of the necessary interventions and actions to optimize the manufacturing process, the standard deviation of drained weight was significantly reduced by 51.02%, with a 99.97% decrease in the number of parts per million defectives. Thus, the yield of the production process was improved by 8.24%. The estimated annual savings from this project were US$ 228,000 resulting from reduced rejection and rework. Practical implications This research may be used in packaging olives production systems as a tool for managers and engineers planning to increase productivity and efficiency while also improving product quality. The study also provided the organization with helpful actions that will be used to guide future Six Sigma operations management on the system. Thus, practical guidelines and solutions are provided. Originality/value In this project, for the first time, the Six Sigma methodology has been applied to solve a real-world problem in the packaging olives manufacturing system and to show that the DMAIC approach may assist to improve the efficiency of their operations and hence contribute to their quest toward continuous improvement.

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“…Define, measure, analyze, improve and control processes for improving systems are widely used in industrial production [29][30][31][32] and hospital management. [33][34][35] The DMAIC process begins by defining problems, identifying the main causes, and proposing relevant solutions.…”

Section: Introductionmentioning

confidence: 99%

“…In addition, the DMAIC method is widely used in the manufacturing industry to improve the manufacturing process and reduce production costs. [30][31][32] This method is used to improve the implementation of medical technologies 34 to improve the effectiveness (quality) and efficiency of surgical procedures, 33 but is not used to reduce medical expenditure. Improving the effectiveness (quality) and efficiency of surgical procedures 33 have not been used to reduce healthcare costs.…”

Section: Introductionmentioning

confidence: 99%

Reducing abnormal expenses in national health insurance based on a control chart and decision tree-driven define, measure, analyze, improve and control process

Chen,

Liu

2023

Health Informatics J

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This study examined the cost of medical insurance for “sepsis” treatment in Taiwan. We applied statistical tests, cost control charts, and C5.0 decision trees using the define, measure, analyze, improve and control (DMAIC) process to mine data on Diagnosis-Related Groups (DRGs) and clinics that reported expense anomalies and disposal costs. Analyzing 353 valid samples (application fees) from four DRGs, 70 clinics, and 15 input variables, abnormalities in application fees for adults (age ≧18 years old) with comorbidities or complications was significant (95% confidence interval) in one DRG and nine clinics. Four input variables (ward charge, treatment fee, laboratory fee, and pharmaceutical service charge) had a significant impact. Improvements or controls should be prioritized for three clinics (Nos. 49, 44, and 14) and two input variables (treatment and laboratory fees). This model can be replicated to ascertain excess medical expenditures and improve the efficiency of medical resource use.

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Waste reduction of polypropylene bag manufacturing process using Six Sigma DMAIC approach: A case study

Cited by 14 publications

References 38 publications

An Application of Six Sigma for Optimality of Medium Density Fiberboard Production

An Application of Six Sigma for Optimality of Medium Density Fiberboard Production

Application of Six Sigma methodology using DMAIC approach for a packaging olives production system: a case study

Reducing abnormal expenses in national health insurance based on a control chart and decision tree-driven define, measure, analyze, improve and control process

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