Title: Reducing the cost of poor quality and improving process output by adopting a Six Sigma DMAIC tool: a case study

Authors: Priyank Srivastava; Melfi Alrasheedi; Prabhakar Kaushik; Shubham Sharma

Addresses: Department of Mechanical Engineering, Amity University, Noida, India ' Department of Quantitative Methods, School of Business, King Faisal University, Saudi Arabia ' Department of Mechanical Engineering, U.I.E.T., Maharishi Dayanand University, Rohtak, India ' Department of Mechanical Engineering, Amity University, Noida, India

Abstract: This study emphasises the real time application of Six-Sigma DMAIC (define-measure-analyse-improve-control) methodology in a manufacturing organisation to reduce the COPQ (cost of poor quality) thereby improving process output. The suspected sources of variation (SSV) for housing pool, were listed by conducting a survey and brainstorming session, followed by measuring and analysing the data using gage R&R (repeatability and reproducibility), paired comparison and multi-vary analysis. Its application to the process led to a shift in sigma level from 3.09 to 4.62 reducing the COPQ by Rs.1, 86,000 for 2 months. This paper can be used as reference by the practitioners and researchers for quality improvement projects and the study could be a paradigm initiative towards high quality products and services at low cost for every manufacturing industry. This study rediscovers and strengthens the already known revolutionary impacts of Six-Sigma DMAIC on productivity improvement and its simplistic application in the manufacturing industry.

Keywords: Six Sigma; DMAIC; cost of poor quality; COPQ; gage R&R; suspected sources of variations; SSVs.

DOI: 10.1504/IJSSCA.2021.120222

International Journal of Six Sigma and Competitive Advantage, 2021 Vol.13 No.1/2/3, pp.195 - 216

Received: 18 Jun 2020
Accepted: 16 Nov 2020
Published online: 11 Jan 2022 *

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