International Journal of Six Sigma and Competitive Advantage (8 papers in press)
Applying Lean Six Sigma Methods to Improve Infectious Waste Management in Hospitals
by Nasim Nabiyouni, Matthew J. Franchetti
Abstract: This work encompasses optimizing red bag waste management program by using Lean Six-Sigma methodology in a Toledo area hospital. Essentially increasing value by decreasing defects and managing disposal frequency. The author conducted full process analysis of red bag waste management including the human factor, economic, environmental, assessments of entire process by implementing Lean Six Sigma approach. However numbers of papers have applied Lean Six Sigma method to improve quality factors in healthcare, no single publication has considered all areas that are covered in this study. The data illustrates proper disposal can minimize waste by 55 percent which would lead to a reduction of environmental impact and a cost savings for the healthcare facility.
Keywords: Six sigma; Lean; Infectious waste management; Red bag waste.
Implementation of Lean Six Sigma Framework in a Large Scale Industry: a case study
by Rajeev Trehan, Ajay Gupta, Mohit Handa
Abstract: In the present competitive scenario most of the companies are usong improvement strategies like lean and six sigma for obtaining good quality products, reduction in overall cost and for enhancing availability of equipment. Lean and six sigma are two different tools which are used in combination for operational excellence. It provides a frame work for waste reduction and elimination of non-value added activities along with variability reduction tools.
Lean tools reduce the waste and non-value adding activity and enhance the effectiveness of equipment, tools and machines. Six sigma tools helps in decision making based on data which finally reduce the variability in the process. In this case study, lean six sigma frame work is implemented to reduce the defects which occurred during the manufacturing process in a bulb manufacturing company in India. The framework used combines the lean as well as six sigma tools to mitigate the defects and increase the customer satisfaction.
Keywords: Lean; Six sigma; Case study; Frame work.
Identification of components and parameters contributing to noise in transmission through the use of Shainin techniques
by Ramnendra Mandloi, R.C. Gupta, Neeraj Tiwari
Abstract: Growing expectation from global market poses challenges to the manufacturing industries to provide the best quality products, consistently and at a competitive price. Cost of poor quality has gone up significantly with the traditional approach of controlling the quality. Traditional approaches, e.g. Use of seven QC tools, engineering judgment, etc. are not very effective in solving chronic quality issues in complex multi-variable scenario. In order to meet up the global expectation, apart from efforts to provide robust manufacturing processes, organization needs to explore effective and fast approaches which utilize various advanced techniques in a systematic combination to solve chronic quality issues. This paper demonstrates the systematic use of Shainin techniques to solve chronic quality problem of noise from automotive transmission. Transmission is a complex system having many subassemblies, components and each component in turn has multiple parameters contributing to noise makes transmission noise an extremely complex multi-factorial problem and all previous efforts to solve the problem using engineering judgments and traditional quality tools were ineffective. There was a need for a systematic approach which can first identify contributing components and subassemblies responsible for the noise in transmission followed by identification of contributing parameters. Shainin techniques known as component search and paired comparison have been used sequentially to identify components and subsequently the parameters of components contributing to the noise in the transmission.
Keywords: Shainin; Shainin Techniques; Component Search; Transmission Noise; Parameter Search; Paired Comparison.
A Review of Specification Limits and Control Limits from the Perspective of Six Sigma Quality Processes
by Ravichandran Joghee
Abstract: There is a general understanding that while specification limits represent voice of the customer, control limits address voice of the process. Given that the process is in statistical control, process capability indices are useful in determining the performance of control limits against the set specification limits. However, there are some speculations on the relation between specification limits and control limits, and as a result practitioners find it hard to make use in full or part of specification limits in the construction of control limits. In fact, these two are treated as independent entities until modified control limits are proposed. Modified control limits stress the need for the development of control limits that not only control the process but keep satisfying the specification requirements as well. Due to evolution of technology over the years, high quality processes always attempt to provide products right the first time. That is, the specification requirements are checked for every controlled process and hence this calls for a strong link between control limits and specification limits. A house of quality-like representation can be used to describe such a link. Therefore, of late, the presumption that they are not related is getting void. A quality practitioner is expected to draw the features of specification limits and intertwine the same with the construction of control limits to achieve right the first time. In this regard a critical review on specification limits and control limits is made from the perspective of Six Sigma quality processes and the need for a strong bond between the two is stressed.
Keywords: Control limits; modified control limits; process capability indices; house of quality; right the first time; Six Sigma quality; specification limits.
Analysis of lean practices in manufacturing industries: An ISM approach
by Mahesh Chand, Suraj ., O.P. Mishra
Abstract: The role of Lean Manufacturing (LM) has increased with an increase competition in global market. A customer wants to buy product at lower possible price without compromising with quality. To overcome this problem, the role of lean manufacturing has been introduced. Lean manufacturing is capable for waste reduction without compromising with quality and productivity. To fulfill this purpose, thirteen (13) practices of LM have been identified through literature review and expert opinion from academic and industries. To identify the cross impact of LM practices, an Interpretive Structural Modelling (ISM) approach have been utilized to find interrelation between these LM practices using MICMAC analysis. Results of this analysis are highly beneficial towards the implementation in industries getting lean.
Keywords: Lean manufacturing; Interpretive structural modelling; practices.
Leanness Production System through Improving of Upstream Process based on Check-Act-Plan-Do (CAPDo) Cycle
by Che Ani Mohd Norzaimi, Kamaruddin Shahrul, Abdul Azid Ishak
Abstract: In this paper, upstream process of production system was studied and improved according to the modified Plan-Do-Check-Act (PDCA) cycle, known as Check-Act-Plan-Do (CAPDo). The PDCA cycle has been widely recognized and utilized by the industrial practitioners, but most of focus on the production processes and less consideration to the upstream process. This research has been conducted by reviewing the current trend of the continuous improvement program, and developed systematic approach of upstream process to improve the production efficiency based on CAPDo cycle because it was consists of predecessor works of the production system, and failure or inefficient will cause production delinquency. The result as implemented in a selected case study industry shows significant process improvement for upstream process. The waiting time of the production process due to misaligned time of the pre-preparation part has been identified as a root cause and this issue has been solved through the systematic approach.
Keywords: upstream process; production system; PDCA; CAPDo; predecessor works.
Dynamic Sigma-TRIZ Solution Model for Manufacturing Improvement and Innovation, Case study in Thailand.
by Jakrapong Karnjanasomwong, Natcha Thawesaengskulthai
Abstract: The aim of this research is to examine how improvement and innovation methodology can be practically implemented in manufacturing area in Thailand. Six sigma is considered an essential methodology approaching for product and process improvement. The methodology applies 5 Six Sigma phases, DMAIC (Define, Measure, Analyse, Improve and Control) for resolving the respected problems which demonstrated a lot of successful stories for decades. This paper is an attempt to introduce new model of manufacturing improvement and innovation which mainly based on DMAIC phases. Dynamic Sigma-TRIZ Solution Model is proposed to enhance the opportunity of deploying improvement and creating innovative solutions in manufacturing process whereas that Dynamic Sigma-TRIZ Principle Matrix database was created from 107 examined projects and also keep updating regularly once additional problems or opportunities got resolved. The paper discussed the real-life cases when Dynamic Sigma-TRIZ Solution Model was implemented successfully in resolving manufacturing problems in different aspects.
Keywords: Six Sigma; TRIZ; Big Data and Analytics; Manufacturing; Competitive Advantage.
Factory-in-Factory (FiF) Concept as a New Business Model for Automotive Production System
by Che Ani Mohd Norzaimi, Kamaruddin Shahrul, Abdul Azid Ishak
Abstract: In this research, a review of the continuous improvement program concepts and applications as employed in the automotive manufacturing ecosystem is analysed based on published articles. The objective of this study is to develop a systematic Factory-in-Factory (FiF) framework of production system by minimizing wastes according to the unresolved issues of the current continuous improvement program. The outcomes obtained from evaluation of the current trend in the continuous improvement programs show that even though the establishment of continuous improvement has been a key to successful business model, there are significant unresolved issues with regards to the vendors. To solve the problem, the future trend of business model in the automotive tier system has been introduced which is Tier-0 and a new production system known as Factory-in-Factory (FiF). The objectives of the new production system are to minimize costs and shorten the lead time through wastes elimination.
Keywords: Continuous improvement; automotive manufacturing ecosystem; business model; vendors; Tier-0; Factory-in-Factory (FiF).