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

Research output: Contribution to journalArticle

14 Citations (Scopus)

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.
LanguageEnglish
Pages125-135
JournalJournal of Manufacturing Technology Management
Volume25
Issue number1
DOIs
Publication statusPublished - 28 Feb 2014

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Facings
Six sigma
Six Sigma
Grinding
Methodology
Industry
Sales
Acoustic waves
Problem solving
Black belt
India
Design methodology
Tolerance

Cite this

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title = "An application of Six Sigma methodology for improving the first pass yield of a grinding process",
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.",
author = "Rodney McAdam",
note = "Reference text: Antony, J. and Banuelas, R. (2002), “Critical success factors for the successful implementation of Six Sigma projects in organisations”, TQM Magazine, Vol. 14 No. 2, pp. 92-99. Antony, J., Knowles, G. and Roberts, P. (1999), “Gauge capability analysis: classical versus ANOVA”, Quality Assurance: Good Practice, Regulation and Law, Vol. 6, pp. 173-181. Breyfogle, F.W. III (2003), Implementing Six Sigma: Smarter Solutions Using Statistical Methods, Wiley, New York, NY. Chen, J.C., Li, Y. and Cox, R.A. (2009), “Taguchi based Six Sigma approach to optimise plasma cutting process: an industrial case study”, International Journal of Advanced Manufacturing Technology, Vol. 41, pp. 760-769. Dale,B.G.,Wiele,T. and Iwaarden, J. (2007), Managing Quality, 5th ed., Blackwell Publishers,Oxford. Draper, N.R. and Smith, H. (2003), Applied Regression Analysis, 3rd ed., Wiley, New York, NY. Dudewicz, E.J. and Mishra, S.N. (1988), Modern Mathematical Statistics, Wiley, New York, NY. JMTM 25,1 134 Gijo, E.V. (2011), “Eleven ways to sink your Six Sigma project”, Six Sigma Forum Magazine, Vol. 11 No. 1, pp. 27-29. Gijo, E.V. and Rao, T.S. (2005), “Six Sigma implementation – hurdles and more hurdles”, Total Quality Management & Business Excellence, Vol. 16 No. 6, pp. 721-725. Gijo, E.V. and Scaria, J. (2012), “Product design by application of Taguchi’s robust engineering using computer simulation”, International Journal of Computer Integrated Manufacturing, Vol. 25 No. 9, pp. 761-773. Gijo, E.V., Scaria, J. and Antony, J. (2011), “Application of Six Sigmamethodology to reduce defects of a grinding process”,Quality&ReliabilityEngineering International,Vol. 27No. 8, pp. 1221-1234. Goh, T.N. (2011), “Six Sigma in industry: some observations after twenty-five years”, Quality & Reliability Engineering International, Vol. 27 No. 2, pp. 221-227. Grant, E.L. and Leavenworth, R.S. (2000), Statistical Quality Control, 7th ed., Tata McGraw-Hill, New Delhi. Harry, M.J. and Schroeder, R. (2000), Six Sigma: The Breakthrough Management Strategy Revolutionizing the World’s Top Corporations, Currency Book, Doubleday, New York, NY. Hoerl, R.W. (2001), “Six Sigma black belts: what do they need to know? (with discussion)”, Journal of Quality Technology, Vol. 33 No. 4, pp. 391-435. Keller, P.A. (2001), Six Sigma Deployment, Quality Publishing House, Tucson, AZ. Knowles, G., Antony, J. and Vickers, G. (2003), “Implementing evaluation of the measurement process in an automotive manufacturer: a case study”, Quality & Reliability Engineering International, Vol. 19 No. 5, pp. 397-410. Kumar, M., Antony, J. and Cho, R. (2009), “Project selection and its impact on the successful deployment of Six Sigma”, Business Process Management Journal, Vol. 15 No. 5, pp. 669-686. Lo, W.C., Tsai, K.M. and Hsieh, C.Y. (2009), “Six Sigma approach to improve surface precision of optical lenses in the injection moulding process”, International Journal of Advanced Manufacturing Technology, Vol. 41, pp. 885-896. Montgomery, D.C. (2002), Introduction to Statistical Quality Control, 4th ed., Wiley, New York, NY. Montgomery, D.C. and Peck, E.A. (1982), Introduction to Linear Regression Analysis, Wiley, New York, NY. Montgomery, D.C. and Woodall, W.H. (2008), “An overview of Six Sigma”, International Statistical Review, Vol. 76 No. 3, pp. 329-346. Pande, P., Neuman, R. and Cavanagh, R. (2000), The Six Sigma Way: How GE, Motorola and Other Top Companies are Honing Their Performance, McGraw-Hill, New York, NY. Ross, P.J. (1996), Taguchi Techniques for Quality Engineering, McGraw-Hill, New York, NY. Snee, R.D. and Hoerl, R.W. (2003), Leading Six Sigma: A Step by Step Guide Based on Experience at GE and Other Six Sigma Companies, Prentice-Hall, Upper Saddle River, NJ. Taguchi, G. (1988), Systems of Experimental Design, Vol. 1/2, UNIPUB and American Supplier Institute, New York, NY. Wu, C.F.J. and Hamada, M. (2011), Experiments – Planning, Analysis, and Parameter Design Optimization, Wiley, New York, NY. Corresponding author Jiju Antony can be contacted at: jiju.antony@strath.ac.uk",
year = "2014",
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doi = "10.1108/JMTM-12-2011-0109",
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An application of Six Sigma methodology for improving the first pass yield of a grinding process. / McAdam, Rodney.

Vol. 25, No. 1, 28.02.2014, p. 125-135.

Research output: Contribution to journalArticle

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AU - McAdam, Rodney

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AB - 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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