Reducing failure rate at high voltage (HV) testing of insulator using Six Sigma methodology

Darshak A. Desai · Aurangzeb Javed Ahmed Shaikh

10 citations0/0 files storedInternational Journal of Productivity and Performance Management

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

Abstract

Purpose This paper, a case study, aims to illustrate the application of Six Sigma in a small-scale ceramic manufacturing industry. The purpose of this paper is to demonstrate the empirical application of DMAIC methodology to reduce failure rate at high voltage (HV) testing of one of the most critical products, insulator. Design/methodology/approach The case study is based on primary data collected from a real-life situation prevailing in the industry. The case study methodology adopted here is at one small-scale unit wherein the authors have applied DMAIC methodology and observed and recorded the improvement results, especially, reduction in failure rate at HV testing of insulator and, thus, increase in Sigma level. Findings The results found after implementation of the solutions are very significant. The rejection percentage has been reduced from 0.5 to 0.1 percent and consequently the Sigma level has been improved from 4.4 to 5.0. Research limitations/implications This success story can be a guiding roadmap for other such industries to successfully implement Six Sigma to improve quality, productivity and profitability. Practical implications This case study will serve as one of the resource bases for the industries which have till not implemented Six Sigma and benefited from the same. Social implications Improved quality and productivity leads to better economy. This case will help industries to serve the society with better economy with improved quality and productivity. Originality/value Though ceramic industries in India are having enormous potential for growth, majority of them, especially, small and medium industries are either not aware of or not implementing Six Sigma to reap its multidimensional benefits of improving quality, productivity and profitability. This study highlights the benefits reaped by small-scale ceramic manufacturing industry opening up the avenues for its application at other such organizations.

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References

2002Six Sigma: a goal‐theoretic perspective 2010Lean Six Sigma – getting better all the time 2011Six Sigma vs Lean 2009Assessing the status of six sigma implementation in the Indian industry 2008Can Six Sigma be effectively implemented in SMEs?2013Application of Six-Sigma DMAIC methodology to sand-casting process with response surface methodology 2011A case study 2013Six Sigma implementation: a qualitative case study using grounded theory

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