An application of Six Sigma methodology for improving the first pass yield of a grinding process

E.V. Gijo · Jiju Antony · Maneesh Kumar · Rodney McAdam

55 citations0/0 files storedJournal of Manufacturing Technology Management

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Quality and Supply Management Management and Optimization Techniques Management Systems and Quality Improvement

Abstract

Purpose – The purpose of this paper is to illustrate the power of the Six Sigma methodology in improving the first pass yield of a high-precision grinding process in the manufacture of automotive products. Design/methodology/approach – The paper follows a case study approach showing how theory has been put into practice. The case study was executed in a leading automotive company based in India. Findings – The application of the Six Sigma methodology resulted in a reduction of tolerance-related problems and improved the first pass yield from 85 to over 99 per cent. A number of tools and techniques in the Six Sigma tool box have been utilised for data analysis and drawing valid and sound conclusions. The implementation of the Six Sigma methodology has demonstrated a saving of US$70,000 in addition to the customer-facing benefits of improved quality on returns and sales. Practical implications – The results of the case study have provided greater stimulus within the production facilities for wider application of the methodology as a powerful problem solving methodology. Moreover, this case study sets the foundation for many other projects within the business. Originality/value – The paper is valuable to many Six Sigma black belts, practitioners of Six Sigma and researchers in terms of understanding the systematic application of the methodology in a real world situation.

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References

1992Introduction to Statistical Quality Control 1989Taguchi Techniques for Quality Engineering 2001Experiments - Planning, Analysis and Parameter Design Optimization 2000The Six Sigma Way: How GE, Motorola, and Other Top Companies are Honing Their Performance 1990Statistical Quality Control 1999Six Sigma: The Breakthrough Management Strategy Revolutionizing the World's Top Corporations 2000Implementing Six Sigma: Smarter Solutions Using Statistical Methods 2002Critical success factors for the successful implementation of six sigma projects in organisations

Cited by

2018Critical review and analysis of measuring the success of Six Sigma implementation in manufacturing sector 2019Integration of value stream mapping with DMAIC for concurrent Lean-Kaizen: A case study on an air-conditioner assembly line 2017Development of Six Sigma methodology to improve grinding processes 2020Application of Six Sigma methodology in an Indian chemical company 2016The underlying factorial structure and significance of the Six Sigma difficulties and critical success factors

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