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Application of Six Sigma methodology in a small‐scale foundry industry

Application of Six Sigma methodology in a small‐scale foundry industry Purpose – The purpose of this article is to illustrate how the Six Sigma methodology was applied to a small‐scale foundry industry to reduce the rejections and rework in one of its processes. Design/methodology/approach – The research reported in this paper is based on a case study carried out in an industry using the Six Sigma Define‐Measure‐Analyze‐Improve‐Control (DMAIC) approach and its application in improving the leaf spring manufacturing process of a foundry shop. Findings – The root causes for the problem of rejection and rework were identified through data‐based analysis at different stages in the project. The process parameters were optimized and measures for sustainability of the results were incorporated in the process. As a result of this study, the overall rejection was reduced from 48.33 to 0.79 per cent, which was a remarkable achievement for this small‐scale industry. This was leading to improvement in on‐time delivery to the customer. The finance department of the company estimated the annualized savings due to the reduction in rejection and was to the tune of USD8,000 per year. Research limitations/implications – The paper is based on a single case study executed in a company, and hence, there is limitation in generalizing the specific results from the study. However, the approach adopted and the learning from this study can be generalized. Originality/value – This article illustrates the step‐by‐step application of Six Sigma DMAIC methodology in a small‐scale foundry industry to solve an age‐old problem in the organization. Thus, this article will be helpful for those professionals who are interested in implementing Six Sigma to such industries. http://www.deepdyve.com/assets/images/DeepDyve-Logo-lg.png International Journal of Lean Six Sigma Emerald Publishing

Application of Six Sigma methodology in a small‐scale foundry industry

International Journal of Lean Six Sigma , Volume 5 (2): 19 – May 27, 2014

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References (47)

Publisher
Emerald Publishing
Copyright
Copyright © 2014 Emerald Group Publishing Limited. All rights reserved.
ISSN
2040-4166
DOI
10.1108/IJLSS-09-2013-0052
Publisher site
See Article on Publisher Site

Abstract

Purpose – The purpose of this article is to illustrate how the Six Sigma methodology was applied to a small‐scale foundry industry to reduce the rejections and rework in one of its processes. Design/methodology/approach – The research reported in this paper is based on a case study carried out in an industry using the Six Sigma Define‐Measure‐Analyze‐Improve‐Control (DMAIC) approach and its application in improving the leaf spring manufacturing process of a foundry shop. Findings – The root causes for the problem of rejection and rework were identified through data‐based analysis at different stages in the project. The process parameters were optimized and measures for sustainability of the results were incorporated in the process. As a result of this study, the overall rejection was reduced from 48.33 to 0.79 per cent, which was a remarkable achievement for this small‐scale industry. This was leading to improvement in on‐time delivery to the customer. The finance department of the company estimated the annualized savings due to the reduction in rejection and was to the tune of USD8,000 per year. Research limitations/implications – The paper is based on a single case study executed in a company, and hence, there is limitation in generalizing the specific results from the study. However, the approach adopted and the learning from this study can be generalized. Originality/value – This article illustrates the step‐by‐step application of Six Sigma DMAIC methodology in a small‐scale foundry industry to solve an age‐old problem in the organization. Thus, this article will be helpful for those professionals who are interested in implementing Six Sigma to such industries.

Journal

International Journal of Lean Six SigmaEmerald Publishing

Published: May 27, 2014

Keywords: Six Sigma; DMAIC; ANOVA; Taguchi method

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