Six Sigma is being Implemented all over the World as a successful Quality Improvement
Methodology. This article provides a description of Six Sigma Project implemented at Local manufacturing
Company. The Company Manufactures Pump Casings where it was receiving high nonconformance rate that
resulted in to Rejection of Product. This study deals with Six Sigma DMAIC methodology implementation and
gives a frame work of how the non-conformance rate was first monitored and then brought in to acceptance
limits. A complete Coverage of the statistical analysis performed during the study is given and results are
shown to describe that how Six Sigma helped the Project members to Improve Quality of Pump casings at
manufacturing facility.
Global Manager Group has prepared presentation to provide information regarding documentation requirements for revised IATF 16949:2016 Certification. It described all primary documents like manual, procedures, plans, audit checklist, etc in details.
For further information about IATF 16949:2016 documentation requirements visit @ https://www.globalmanagergroup.com/
six sigma DMAIC approach for reducing quality defects of camshaft binding pro...Niranjana B
Data collection for 11 months revealed that 26% of the defects are due to improper camshaft binding. The six sigma approach involves DMAIC approach with statistical tools involved in each stage. The main root are identified and improvements are implemented. The quality is improved by reducing the number of defects
The Autonomous Maintenance Framework Poster highlights the key Autonomous Maintenance process, methods and tools.
The AM Framework Poster comes in two themes: color and monochrome. Formatted in PDF, the poster can be easily printed on an A3-sized paper.
The AM Framework Poster complements the Autonomous Maintenance training presentation materials. It is an effective tool that can be printed and distributed to attendees of your TPM or AM awareness or workshop session. It serves as a takeaway and summary of your TPM or AM presentation.
The AM Framework Poster provides a description of the key Autonomous Maintenance process, methods and tools. It includes:
1. Goals of Autonomous Maintenance
2. The Autonomous Maintenance Approach
3. Four Equipment-related Skills for Operators
4. OEE: An Indicator of Equipment Health
5. Three Key Tools for Autonomous Maintenance Activities
6. Seven Steps of Autonomous Maintenance
7. Autonomous Maintenance Team Improvement Process
8. The 5Ws and 1H of Improvement
9. An Effective TPM Program Extends the Useful Life of Equipment.
Global Manager Group has prepared presentation to provide information regarding documentation requirements for revised IATF 16949:2016 Certification. It described all primary documents like manual, procedures, plans, audit checklist, etc in details.
For further information about IATF 16949:2016 documentation requirements visit @ https://www.globalmanagergroup.com/
six sigma DMAIC approach for reducing quality defects of camshaft binding pro...Niranjana B
Data collection for 11 months revealed that 26% of the defects are due to improper camshaft binding. The six sigma approach involves DMAIC approach with statistical tools involved in each stage. The main root are identified and improvements are implemented. The quality is improved by reducing the number of defects
The Autonomous Maintenance Framework Poster highlights the key Autonomous Maintenance process, methods and tools.
The AM Framework Poster comes in two themes: color and monochrome. Formatted in PDF, the poster can be easily printed on an A3-sized paper.
The AM Framework Poster complements the Autonomous Maintenance training presentation materials. It is an effective tool that can be printed and distributed to attendees of your TPM or AM awareness or workshop session. It serves as a takeaway and summary of your TPM or AM presentation.
The AM Framework Poster provides a description of the key Autonomous Maintenance process, methods and tools. It includes:
1. Goals of Autonomous Maintenance
2. The Autonomous Maintenance Approach
3. Four Equipment-related Skills for Operators
4. OEE: An Indicator of Equipment Health
5. Three Key Tools for Autonomous Maintenance Activities
6. Seven Steps of Autonomous Maintenance
7. Autonomous Maintenance Team Improvement Process
8. The 5Ws and 1H of Improvement
9. An Effective TPM Program Extends the Useful Life of Equipment.
[Note: This is a partial preview. To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
Focused Improvement is one of the key pillars of TPM. Also known as Kobetsu Kaizen in Japanese, this presentation provides shopfloor TPM teams, including production workers, maintenance technicians, engineers, and managers a strong framework for further improving equipment performance as well as eliminating the 16 big losses.
As distinguished from Autonomous Maintenance, in which the main goal is to restore basic conditions to prevent accelerated deterioration, Focused Improvement looks at weaknesses that everyone previously thought were unavoidable.
Developed by our JIPM-certified TPM Instructor, this training presentation teaches you the knowledge and skills for planning, organizing and implementing Focused Improvement activities in the workplace. It includes the step by step process and the common analytical tools and techniques for Focused Improvement.
LEARNING OBJECTIVES
1. Understand what is Focused Improvement and why it is important in TPM implementation
2. Acquire knowledge on how to plan and organize Focused Improvement activities
3. Describe the Focused Improvement approach and the common analytical tools
4. Gain practical tips for sustaining Focused Improvement activities and the key factors for success
CONTENTS
1. Introduction to Focused Improvement
2. What is Focused Improvement?
3. Planning and Organizing for Focused Improvement
4. The 8 Steps of Focused Improvement
5. Common Tools & Techniques for Focused Improvement
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
Q-C-D is a management approach originally developed to help manufacturing companies. It is a methodology that is still used today. Lean Manufacturing, Six Sigma, Kaizen, and Toyota Production Systems (TPS) are all based upon the original Q-C-D methodology. All require data to make decisions.
Quality Maintenance is an "advanced" pillar of TPM and aims to assure zero defect conditions. Also known as Hinshitsu Hozen in Japanese, it does this by understanding and controlling the process interactions between the 4Ms - manpower, material, machines and methods that could enable defects to occur. The key is to prevent defects from being produced in the first place, rather than screening them out through inspection systems after they have been produced. Controlling quality through its causes is the essence of Quality Maintenance.
Developed by our JIPM-certified TPM Instructor, this presentation teaches the key concepts, principles and philosophy of Quality Maintenance, the 4M conditions that are essential for defect-free production, as well as the step-by-step process for Quality Maintenance.
LEARNING OBJECTIVES
1. Understand the key concepts, principles and philosophy of Quality Maintenance
2. Acquire knowledge on the 4M conditions and the prerequisites for promoting Quality Maintenance
3. Describe the 8-step process of Quality Maintenance and the key analytical tools and techniques
CONTENTS
1. Key Concepts & Philosophy of Quality Maintenance
2. 4M Conditions - The Determinants of Quality
3. The 8 Steps of Quality Maintenance
4. Key Tools & Techniques for Quality Maintenance
5. Towards Excellence in Quality Maintenance
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
The DMAIC Process is a process in which we first Define the problem then we measure the same problem then in the third step we analyze the problem. In the fourth step we try to improve the process and at the fifth step we try to control the limits or the process we want to imporve.
You can also read more at https://industrialdocs.blogspot.com
Design, Analysis and Implementation of Modified Luby Transform CodeIOSR Journals
Abstract : Bit losses in erasure channels like computer networks are of great concern. The existing methods to combat bit losses are either inefficient or time consuming due to the retransmission protocols involved. Through this paper, we propose a Modified Luby Transform (MLT) coding scheme to efficiently transmit data over live computer networks. The MLT code can combat bit losses as well as eliminate the need for retransmission. The usability and reliability of the proposed MLT code is verified by testing it on a live computer network. Keywords : Erasure channel, Fountain Codes, Luby Transform Codes , Wired Networks, Wireless Networks
Impact of Trade Associations on Entrepreneurial Traits in Nigeria’s Transport...IOSR Journals
The focus of this study is to determine the extent to which the roles of trade associations foster entrepreneurial traits in Nigeria’s road transport industry. This paper offers an analytical assessment of the contribution of trade associations towards development of entrepreneurial traits. To do this, the survey method was adopted for the study and questionnaires were used as data collection method. A random of one hundred and forty four (144) trade associations in Nigeria’s road transport industry were selected for the study out of a population of two hundred and twenty four (224) trade associations with seven hundred and twenty (720) respondents. For completeness, a sample of six hundred and fifty seven (657) related organizations (infinite population) were included in the study. Therefore a total of one thousand, three hundred and seventy seven (1377) questionnaires were used for the study. The data collected were measured in 5-point likert scale with a hypothesized mean of 3.00. data analysis revealed that overall mean scores of trade associations’ pro-competitive and anti-competitive roles on entrepreneurial traits were 1.9346 and 4.4188 respectively. The test of hypothesis using two sample z-test showed that the Z- calculated value for differences in the two mean scores was 216.0147 with significance probability of ˂ 0.0001 which is less than 0.05. Thus the test was significant at 5% level of significance (P˂0.05). We therefore reject the null hypothesis and accept the alternative hypothesis. Consequently we conclude that the effect of anticompetitive role is significantly higher than that of pro-competitive role of trade associations on the development of entrepreneurial traits in Nigeria’s transport industry
[Note: This is a partial preview. To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
Focused Improvement is one of the key pillars of TPM. Also known as Kobetsu Kaizen in Japanese, this presentation provides shopfloor TPM teams, including production workers, maintenance technicians, engineers, and managers a strong framework for further improving equipment performance as well as eliminating the 16 big losses.
As distinguished from Autonomous Maintenance, in which the main goal is to restore basic conditions to prevent accelerated deterioration, Focused Improvement looks at weaknesses that everyone previously thought were unavoidable.
Developed by our JIPM-certified TPM Instructor, this training presentation teaches you the knowledge and skills for planning, organizing and implementing Focused Improvement activities in the workplace. It includes the step by step process and the common analytical tools and techniques for Focused Improvement.
LEARNING OBJECTIVES
1. Understand what is Focused Improvement and why it is important in TPM implementation
2. Acquire knowledge on how to plan and organize Focused Improvement activities
3. Describe the Focused Improvement approach and the common analytical tools
4. Gain practical tips for sustaining Focused Improvement activities and the key factors for success
CONTENTS
1. Introduction to Focused Improvement
2. What is Focused Improvement?
3. Planning and Organizing for Focused Improvement
4. The 8 Steps of Focused Improvement
5. Common Tools & Techniques for Focused Improvement
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
Q-C-D is a management approach originally developed to help manufacturing companies. It is a methodology that is still used today. Lean Manufacturing, Six Sigma, Kaizen, and Toyota Production Systems (TPS) are all based upon the original Q-C-D methodology. All require data to make decisions.
Quality Maintenance is an "advanced" pillar of TPM and aims to assure zero defect conditions. Also known as Hinshitsu Hozen in Japanese, it does this by understanding and controlling the process interactions between the 4Ms - manpower, material, machines and methods that could enable defects to occur. The key is to prevent defects from being produced in the first place, rather than screening them out through inspection systems after they have been produced. Controlling quality through its causes is the essence of Quality Maintenance.
Developed by our JIPM-certified TPM Instructor, this presentation teaches the key concepts, principles and philosophy of Quality Maintenance, the 4M conditions that are essential for defect-free production, as well as the step-by-step process for Quality Maintenance.
LEARNING OBJECTIVES
1. Understand the key concepts, principles and philosophy of Quality Maintenance
2. Acquire knowledge on the 4M conditions and the prerequisites for promoting Quality Maintenance
3. Describe the 8-step process of Quality Maintenance and the key analytical tools and techniques
CONTENTS
1. Key Concepts & Philosophy of Quality Maintenance
2. 4M Conditions - The Determinants of Quality
3. The 8 Steps of Quality Maintenance
4. Key Tools & Techniques for Quality Maintenance
5. Towards Excellence in Quality Maintenance
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
The DMAIC Process is a process in which we first Define the problem then we measure the same problem then in the third step we analyze the problem. In the fourth step we try to improve the process and at the fifth step we try to control the limits or the process we want to imporve.
You can also read more at https://industrialdocs.blogspot.com
Design, Analysis and Implementation of Modified Luby Transform CodeIOSR Journals
Abstract : Bit losses in erasure channels like computer networks are of great concern. The existing methods to combat bit losses are either inefficient or time consuming due to the retransmission protocols involved. Through this paper, we propose a Modified Luby Transform (MLT) coding scheme to efficiently transmit data over live computer networks. The MLT code can combat bit losses as well as eliminate the need for retransmission. The usability and reliability of the proposed MLT code is verified by testing it on a live computer network. Keywords : Erasure channel, Fountain Codes, Luby Transform Codes , Wired Networks, Wireless Networks
Impact of Trade Associations on Entrepreneurial Traits in Nigeria’s Transport...IOSR Journals
The focus of this study is to determine the extent to which the roles of trade associations foster entrepreneurial traits in Nigeria’s road transport industry. This paper offers an analytical assessment of the contribution of trade associations towards development of entrepreneurial traits. To do this, the survey method was adopted for the study and questionnaires were used as data collection method. A random of one hundred and forty four (144) trade associations in Nigeria’s road transport industry were selected for the study out of a population of two hundred and twenty four (224) trade associations with seven hundred and twenty (720) respondents. For completeness, a sample of six hundred and fifty seven (657) related organizations (infinite population) were included in the study. Therefore a total of one thousand, three hundred and seventy seven (1377) questionnaires were used for the study. The data collected were measured in 5-point likert scale with a hypothesized mean of 3.00. data analysis revealed that overall mean scores of trade associations’ pro-competitive and anti-competitive roles on entrepreneurial traits were 1.9346 and 4.4188 respectively. The test of hypothesis using two sample z-test showed that the Z- calculated value for differences in the two mean scores was 216.0147 with significance probability of ˂ 0.0001 which is less than 0.05. Thus the test was significant at 5% level of significance (P˂0.05). We therefore reject the null hypothesis and accept the alternative hypothesis. Consequently we conclude that the effect of anticompetitive role is significantly higher than that of pro-competitive role of trade associations on the development of entrepreneurial traits in Nigeria’s transport industry
Product Development, Biochemical and Organoleptic Analysis of a Sports Drink.IOSR Journals
Abstract: There is a large amount of evidence showing that an individual undergoing dehydration (during a
tournament or the exercise regimen) has a negative impact on performance. Thus restoration of this fluid
balance must be achieved. Sports drinks are ideally placed to fill both these roles. A sports drink is a beverage
designed to help athletes rehydrate, as well as replenish electrolytes, sugars and other nutrients that are lost or
depleted after strenuous exercise, training or competition. However, in a sports drink, a variety of substances
and nutrients are dissolved in water to make the final product. Not only that, a variety of fruit juices can also be
added which provide natural flavor and color rather than adding the artificial ones. In this project, a sports
drink was developed mainly using Anandi variety of pomegranate (Punica granatum) and kokum (Garcinia
indica). These fruits not only provide natural flavor and color, but also minerals which are essential for the
enhancement of athletes’ performance. These fruits are available throughout the year and hence, were selected.
Proximate, biochemical, microbiological and sensory properties of the developed product were analyzed. The
sports drink product was isotonic. It contained 6.33 % of carbohydrate, and 105.6 mg/100 ml of vitamin C
which allows the sports drink for easy gastric emptying and intestinal absorption. The electrolytes present in the
sports drink were similar to those lost through sweating and were obtained as; potassium (33.99 mg %), sodium
(65.75 mg %), phosphate (4.085mg %), chloride (394.4 mg %), calcium (8 mg %), magnesium (4.86 mg %) and
iron (0.72 mg %). Results from the Minimum Inhibitory Concentration and Real Time Polymerase Chain
Reaction (RT- PCR) confirmed the bactericidal property of the sports drink. The presence of antioxidants, led to
the enhancement of the formulation, making it a better sports drink. Also, the study examined the extent to which
the sports drink caused dental erosion as compared to that of the branded sports drink. The effect of the sports
drink in comparison to that of water, on the performance of young sprinters was also analyzed and the sports
drink provided positive results. Sensory evaluation gave an idea regarding the overall acceptability of the
developed sports drink. Keywords: Biochemical, microbiological, organoleptic, sports drink, minimum inhibitory concentration, dental
erosion.
Wind Turbine Power Generation: Response PredictionIOSR Journals
The worldwide interest has been increasing about wind energy for power generation purpose due to
continue increase in fuel cost and the need to have clean source of energy. Wind energy may enhance the power
generation capabilities and maximize its capacity factor, inurn participate in generating power at lower cost. It
has also been notice that renewable power generation through wind energy is also the fast growing energy
technology. The optimization of the efficiency of wind turbine is prudent to complete the conventional power
sources. Wind Turbine Power Generation (WTPG) is a complex phenomenon to understand since the real
process has depends upon the Wind Velocity and the relative turbine dimensions and the outside climatological
parameter like Wind Velocity (WV) nature of wind, etc. In this paper an effort has been made to develop a fuzzy
logic approach to predict an appropriate WTPG considering the WV, AD and Chord Length of Turbine Blades
(CLTB) as input parameters. The complexities of the parameters and the imprecision of linguistic expressions
are taken into consideration; the application combining linguistic variable to optimize WTPG under multiple
conditions is presented in this study.
On Fuzzy - Semi Open Sets and Fuzzy - Semi Closed Sets in Fuzzy Topologic...IOSR Journals
Abstract: The aim of this paper is to introduce the concept of fuzzy - semi open and fuzzy - semi closed sets of a fuzzy topological space. Some characterizations are discussed, examples are given and properties are established. Also, we define fuzzy - semi interior and fuzzy - semi closure operators. And we introduce fuzzy
- t-set, -SO extremely disconnected space analyse the relations between them.
MSC 2010: 54A40, 03E72.
On Spaces of Entire Functions Having Slow Growth Represented By Dirichlet SeriesIOSR Journals
In this paper spaces of entire function represented by Dirichlet Series have been considered. A
norm has been introduced and a metric has been defined. Properties of this space and a characterization of
continuous linear functionals have been established.
“Rover - Remote Operated Vehicle for Extraction and Reconnaissance”IOSR Journals
Inspired from differential drive mechanism of army tank and chain drive of tank for movement of rover. Try to deploy the concept of crane working in rover for extraction purpose. Use the camera for the security purpose and surveillance in rover for the reconnaissance purpose.
Use “pro-engineering software” for designing purpose of rover. It is prototype to explain the concept of differential drive mechanism and its use in robotics.
The Effect Of Planning And Control To Bureaucracy Behavior In The Improving S...IOSR Journals
The main problem in this study is the service quality in the Department of Population and Civil Registration Jakarta is considered optimal. Bureaucratic behavior, presumably as a result of poor planning and oversight that cannot be implemented properly. The purpose of this research is to gain any influence planning on the bureaucratic behavior, monitoring on bureaucratic behavior, and the influence of bureaucratic behavior on the service quality and to obtain a new concept for the development of science and useful and can be applied in the community, especially in the Department of Population and Civil Jakarta. The method used in this study is non-experimental survey method with sampling Stratified Random Sampling. Technical analysis is the data used path analysis. Test the validity of the instrument using the Pearson correlation test product moment and reliability of the instrument using Cronbach alpha The results showed that the positive effect the planning on the bureaucracy behavior, oversight positive effect controlling on the behavior of bureaucracy and positive effect bureaucratic behavior on service quality. The findings in this study are not routinely conducted surveillance dimension thus potentially deviant bureaucracy behavior is not optimal to improve the service quality. The implications of this research are bureaucratic behavior is important in improving Service quality.
Idiosyncratic Effect of Corporate Solvency Management Strategies on Corporate...IOSR Journals
The study identifies and evaluates the association among corporate solvency management strategies and the corporate performance valuation in Chemical industry of Pakistan. The study uses purposive sampling or judgmental sampling for selecting 30 sample companies from the sector; covering 10 years financial statements data ranging from year 2002 to 2011. Balanced panel data is taken for the purpose of study. Levin, Lin & Chu test is used to check the stationarity of data whereas White Test is used to check the heteroskedasticity of data. Panel Least square technique with fixed effects is used to generalize the relationship between studied variables. The study observed that the performance of the chemical sector in terms of market to book value is affected by internal firm and industry specific factors related to solvency management strategic decisions. Findings of the study provide with the overview of historic performance and the potential performance of the selected sector to help policy makers including finance, economics and industry experts for creating value through the idiosyncratic resources.
A Learning and Improvement Model in Entrepreneurial LeadershipIOSR Journals
Currently entrepreneurial leadership has expended and increased momentum as developingmodel of both in research and practice. Though, there is not sufficient knowledgeon the theoretical and intangible basis of this emerging area of analysisandlot of questions are raised up on how to grow entrepreneur leadershipabilities, capabilitiesprecisely in university students. The basicmotive of thistheoretical paper is to slight the gap through offering the theoretical andconceptual basics of entrepreneur leadership. This paper has also examinedvariousfeatures of entrepreneurial education in the perspective of universitygiven entrepreneur-ship programs and then projected a model for entrepreneurial-leadership enlargement. The projected model describes entrepreneurial leadershipenlargementbase on a dynamic progression of “experimental, social interactive,observational and reflective learning” which make available a base for entrepreneur leadership exercise, enlightenment and research.
The efficacy of strategic management processes: An empirical study of Nationa...IOSR Journals
The purpose of this study was to appraise the adequacy of strategic management processes of National Sports Associations (NSAs) in Zimbabwe. Most of Zimbabwe NSAs perform poorly as evidenced by the perennial failure of national teams to qualify for major regional and international tournament. Their strategic management processes appear to be inadequate to meet the modern day environmental challenges. The study used the descriptive survey as the design. A sample of fifty three National Sports Association and Provincial Sports Association chairpersons were randomly selected from a population of seventy nine chairpersons. Hand delivered questionnaires with both open ended and closed questions were used to collect data. Results from the study indicate that most NSAs have core values, corporate objectives, policies and make use of physical structures. However the results also show that the majority of NSAs do not have strategic plans, do not practice strategic management and do not conduct strategic reviews. The results led to the conclusion that the strategic management processes in NSAs are inadequate. The study recommended that NSAs should prioritize strategic management and that both the Sports and Recreation Commission and Zimbabwe Olympic Committee should assist NSAs technically and financially to facilitate the adoption of strategic management principles
Effects of Variable Fluid Properties and MHD on Mixed Convection Heat Transfe...IOSR Journals
The effects of variable Fluid Properties like variation of permeability, porosity, thermal conductivity and magnetic field on Mixed Convection Heat transfer from Vertical Heated Plate Embedded in a Sparsely Packed Porous Medium have been approached numerically. The boundary layer flow in the porous medium is governed by Lapwood – Forchheimer – Brinkman extended Darcy model and the Lorentz force. The natures of these equations are highly non-linear and coupled each other. The non-linear differential equations are non-dimensionalised using the non-dimensional parameter involving Grashoff number Gr, Prandtl number Pr, Hartmann number M, Eckert number E and so on. Similarity transformations are employed and the resulting ordinary differential equations are solved numerically by using shooting algorithm with Runge – Kutta and Newton – Raphson method to obtain velocity and temperature distributions. Besides, skin friction and Nusselt number are also computed for various physical parameters governing the problem under consideration. It is found that the inertial parameter has a significant influence in decreasing the flow field, whereas its influence is reversed on the rate of heat transfer for all values of permeability considered. The effect of Magnetic field is diminution with velocity of the fluid flow. Further, the obtained results under the two limiting conditions were found to be in good agreement with the existing results
Performance Analysis of OFDM in Combating Multipath FadingIOSR Journals
Abstract: Mobile Communication system has been on high rampage for high data transmission over wireless medium with various challenges caused by the transmission Channel. OFDM is been discovered in recent years to deal with this problems because of its ability to elegantly cope with multipath interference. This paper investigates the performance of different modulation schemes using M-ary Phase Shift Keying (M-PSK) and M-ary Quadrature Amplitude Modulation (M-QAM) in information transmission with OFDM technique over Ideal channel AWGN and worst channel Rayleigh Fading channel in terms of Bits Error Rate (BER). Analysis was made for different types of modulation schemes BPSK, QPSK, 4-QAM and 16-QAM gray coded bit mapping. Also, a feasibility of OFDM been used to combat multipath fading was analyzed with comparison between a single carrier technique and OFDM multicarrier technique. Variation between SNR results with respect to BER is plotted to show the trade off differences between the modulation schemes with the result showing that OFDM allows data transmission with minimal error over fading channel than a Single Carrier. Keywords: OFDM, Single Carrier, AWGN, Rayleigh fading, BER, M-ary PSK, M-ary QAM
A survey on context aware system & intelligent Middleware’sIOSR Journals
Abstract: Context aware system or Sentient system is the most profound concept in the ubiquitous computing.
In the cloud system or in distributed computing building a context aware system is difficult task and
programmer should use more generic programming framework. On the basis of layered conceptual design, we
introduce Context aware systems with Context aware middleware’s. On the basis of presented system we will
analyze different approaches of context aware computing. There are many components in the distributed system
and these components should interact with each other because it is the need of many applications. Plenty
Context middleware’s have been made but they are giving partial solutions. In this paper we are giving analysis
of different middleware’s and comprehensive application of it in context caching.
Keywords: Context aware system, Context aware Middleware’s, Context Cache
Climatological Effects of Total Solar Radiation in Awka, NigeriaIOSR Journals
Harmattan, humidity and temperature are amongst some climatological variables that affect solar radiations. In this paper we evaluated the effects of these climatological variables on solar radiation in Awka, Anambra State, Nigeria. The city Awka has the latitude of 6.06oN and longitude of 7.0oE. We took various readings of temperature and humidity from December, 2012 to July 2013 and we observed as expected that solar radiation increased with increase in temperature, while increase in humidity greatly reduces solar energy. The harmattan effect on solar radiation showed less fluctuations in the value of solar radiation during any particular day. The basic problem during this period is dust, which uniformly reduces the solar radiation during any particular day. Observations during the period of measurement showed that the fluctuations during harmattan and high temperature were essentially due to dust which was responsible for the high diffuse nature and attenuation on the solar radiation. The regression co-efficient for the periods under study in the city were determined for use in predicting solar radiation.
Elimination of rework in V Cap by Using Six Sigma MethodologyIJERD Editor
The purpose of this project was to gain a strong understanding of Six Sigma management philosophy, concepts, and practices and to apply this knowledge to creating a Six Sigma academic course or training program. This was done through three main methods: preliminary research and data collection, the creation of a design model for Six Sigma academic course program establishment, and the creation of a Six Sigma academic course program syllabus. The preliminary research consisted of conducting a Six Sigma knowledge survey with the students of Worcester Polytechnic Institute, interviewing a Six Sigma expert, and examining current Six Sigma educational programs in other universities, businesses, and organizations. As a result of our observations, we determined that Six Sigma has become a large part of many companies and should be implemented into more engineering programs at universities nation-wide, including Worcester Polytechnic Institute. This can be done through a project based course, as well as more Six Sigma based Interactive and Major Qualifying Projects.
Operations Management: Six sigma benchmarking of process capability analysis...FGV Brazil
Six sigma benchmarking of process capability analysis and mapping of process parameters.
Author: Jagadeesh Rajashekharaiah
Journal of Operations and Supply Chain Management
Vol 9, No 2 (2016)
FGV's Brazilian School of Public and Business Administration (EBAPE)
Abstract
Process capability analysis (PCA) is a vital step in ascertaining the quality of the output from a production process. Particularly in batch and mass production of components with specified quality characteristics, PCA helps to decide about accepting the process and later to continue with it. In this paper, the application of PCA using process capability indices is demonstrated using data from the field and benchmarked against Six Sigma as a motivation to improve to meet the global standards. Further, how the two important process parameters namely mean and the standard deviation can be monitored is illustrated with the help of what if analysis feature of Excel. Finally, the paper enables to determine the improvement efforts using simulation to act as a quick reference for decision makers. The global benchmarking in the form of Six Sigma capability of the process is expected to give valuable insight towards process improvement.
Six Sigma is a quality management methodology that streamlines and transforms business processes to achieve more with less. Six Sigma Yellow Belt is part of the Six Sigma process improvement certification for quality management.
This TUV SUD's Lean Six Sigma Yellow Belt Certification is one of the most industry-recognized Quality management certifications for professionals across the globe.
To know more about Lean Six Sigma Yellow Belt Certification training's worldwide, please contact us at -
Email :support@invensislearning.com
Phone - US +1-910-726-3695,
Website : https://www.invensislearning.com
Six Sigma as a Quality and Continuous Improvement Strategyvivatechijri
As Global competition hikes, Quality become the highest priority in today manufacturing world.
Competitiveness, innovation and performance are the key words that best define the goals of this business
environment. Under the given circumstance concepts like quality and continuous improvement become important
actors in achieving these goals. These programs were instituted within the 1980s and early 1990s as response to
the “economic growth and manufacturing dominance of Japanese industries”. Most of these programs, are “Justin-Time (JIT), Total Quality Management (TQM), KAIZEN, Poka-yoke” were based partly on the tenets and
results of the Toyota Production System (TPS) that was established in an evolutionary manner since the 1950s
through the work of W. Edwards Deming and Taiichi Ohno. for many years, TQM has been a dominant
management concept for improving competitiveness and financial results. In recent years, however TQM seems
to have lost variety of its nimbus with other concepts and approaches like Lean Enterprise and Six sigma launched
and increasingly stylish. These aims of this paper is to clarify that sigma could also be alternative for its
predecessor i.e. TQM and their similarities and differences to sort out whether the two ideas truly are various
dishes or contain the indistinguishable fixings in various.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
1. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)
e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 7, Issue 4 (Jul. - Aug. 2013), PP 96-112
www.iosrjournals.org
www.iosrjournals.org 96 | Page
Six Sigma Implementation to reduce rejection rate of Pump
Casings at local Manufacturing Company
Faheem Yousaf¹, Dr. Shahid Ikramullah Butt¹, Dr. Riaz Ahmad¹
¹National University of Science and Technology, Islamabad, Pakistan
Abstract: Six Sigma is being Implemented all over the World as a successful Quality Improvement
Methodology. This article provides a description of Six Sigma Project implemented at Local manufacturing
Company. The Company Manufactures Pump Casings where it was receiving high nonconformance rate that
resulted in to Rejection of Product. This study deals with Six Sigma DMAIC methodology implementation and
gives a frame work of how the non-conformance rate was first monitored and then brought in to acceptance
limits. A complete Coverage of the statistical analysis performed during the study is given and results are
shown to describe that how Six Sigma helped the Project members to Improve Quality of Pump casings at
manufacturing facility.
Keywords: Statistical Process Control (SQC), Process Capability Indices, Six Sigma, Variable control chart,
Pareto charts, Standard deviation, Critical to Quality (CTQ), Analysis of Variance (ANOVA), DMAIC, Total
quality Management (TQM)
I. Introduction
In this Era of changing customer needs and demand of highly reliable products have pushed many
manufacturing companies to adopt Total Quality Management (TQM) principles. Globalization and extension
of Product Market has also increased the need of Quality Products at Reasonable cost to Customers. To respond
to these Demands many Companies are implementing different Quality Management Principles at their
manufacturing facilities such as ISO 9000, Just in Time (JIT), Lean Manufacturing, and Kaizan etc. A new and
Improved Quality Improvement Approach called Six Sigma is also becoming Popular in Controlling the Defect
rate and managing the Quality as overall Process Function.
The roots of Six Sigma as a measurement standard can be traced back to Carl Frederick Gauss (1777-
1855) who introduced the concept of the normal curve. Six Sigma as a measurement standard in product
variation can be traced back to the 1920′s when Walter Shewhart showed that three standard deviations from the
process mean is the point where a process requires correction. Many measurement standards (Zero defects etc.)
Later came on the scene but credit for coining the term “Six Sigma” goes to a Motorola engineer named Bill
Smith. (Incidentally, “Six Sigma” is a federally registered trademark of Motorola).
In the early and mid-1980s with Chairman Bob Galvin, Motorola engineers decided that the traditional
quality levels; measuring defects in thousands of opportunities didn’t provide enough granularity. Instead, they
wanted to measure the defects per million opportunities. Motorola developed this new standard and created the
methodology and needed cultural change associated with it. Since then, hundreds of companies around the
world have adopted Six Sigma as a way of doing business.
II. Overview of Statistical Quality Control (SQC)
Quality may be defined as that characteristic which Renders a product or service as having “fitness for
Purpose or use”. There are different reasons why a Product may have poor quality. Statistical Methods play a
central role in Quality improvement Efforts and recognized as an efficient and powerful tool in dealing with the
process control aspects (Montgomery 2003).
Statistical Quality Control (SQC) is the term used to describe the set of statistical tools used by quality
professionals. SQC is used to analyze the quality problems and solve them. Statistical quality control refers to
the use of statistical methods in monitoring and maintaining of the quality of products and services. All the tools
of SQC are helpful in evaluating the quality of services. SQC uses different tools to analyze quality problems.
Descriptive Statistics, Statistical Process Control (SPC) and Acceptance Sampling are the major SQC
Techniques used in Improving Quality of Processes.
2.1. Concept of Variation
Variation is part and parcel of life. The concept of Variation states that no two products will be
perfectly identical even if extreme care is taken to make them Identical in some aspect. The variation in the
quality of Product in any manufacturing process results because of two reasons namely, Chance cause and
2. Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
www.iosrjournals.org 97 | Page
Assignable Cause. A process that is operating with only chance causes of variation is said to be in a state of
control with minor variations in the process. The major objective of SPC is to quickly detect the occurrence of
assignable causes so that investigation of process and corrective action may be taken before many non-
conforming units are manufactured. Finally the eventual goal of SPC is the elimination of variability in the
processes.
2.2. Process Capability
The Process Capability studies are helpful in analyzing the quality and efficiency of the process. The
Process Capability analysis has been widely adopted as the ultimate measure of Performance to evaluate the
ability of a process to satisfy the customers in the form of specifications (English et al 1993).
The Process Capability study helps in designing the product, deciding the acceptance limits of the
process and operators in the operations management (Feigenbaum 1994). The evaluation of process capability is
an important step in process quality improvement (Juran 1991). It is customary to take the Six Sigma Prime
spread in the distribution of the product Quality Characteristic as a measure of process capability. In Process
Capability study of particular process, Six Sigma Prime spread is compared with the difference of Upper
Specification Limit (USL) and the Lower Specification Limit (LSL). The following are the three possible cases.
1. 6s ` > (USL – LSL): In this case, the process spread is greater than the tolerance. So the process is incapable
of meeting the Specification.
2. 6s `= (USL – LSL): In this case, the process spread is exactly equal to the tolerance. So the process is exactly
capable of meeting the specifications.
3. 6s ` < (USL – LSL): In this case, the process spread is less than the tolerance. So the process is capable of
meeting the specifications.
2.3. Process Capability Indices
It is frequently convenient for Engineers to have a simple and quantitative way to express process
capability. One way to do so is through process capability indices. Process capability indices (PCI) are powerful
means of studying the process ability for manufacturing a product that meets specifications (Chen et al 2001).
PCI is defined as the ratio of tolerances to the process spread. Equation (1) describes the way to calculate PCI.
Process Capability Index (PCI) = (USL – LSL)/6s (1)
Where PCI is process Capability indices, USL is upper specification limit, LSL is lower specification
limit and 6s is the six sigma abbreviation.
2.4. Six Sigma
It is the set of practices originally developed by Motorola to systematically improve process by
eliminating defects. Defect is defined as non-conformity of a product or service to its specification. Like its
previous quality improving methodologies six sigma focuses on the following points.
A continuous effort to reduce variation in process outputs is essential to business success.
Manufacturing and business processes can be Measured, Analyzed, Improved and Controlled.
In order to achieve best Quality Improvement results, role of upper management is very critical.
The term Six Sigma refers to a highly capable process that can produce products within specifications.
Process that achieves Six Sigma levels produces only 3.4 defective Products per million opportunities. Main
focus of Six Sigma is to improve all key processes of manufacturing setup and takes quality as a function of
Processes Capability to produce items with in specification.
Six Sigma mainly uses two main methodologies one is called Define, Measure, Analyze, Improve and
Control, usually known as DMAIC and other is Define, Measure, Analyze, Design and Verify, known as
DMADV. Both the methodologies are based on Edwards Deming’s, Plan- Do-Check-Act cycle.
DMADV is used for creating new processes to produce products with minimum defect rate.
Other methodologies that are being used during six sigma implementation are given as.
DCCDI (Define, Customer, Concept, Design And Implement)
CDOC (Conceptualize, Design, Optimize and Control)
DCDOV (Define, Concept, Design, Optimize and Verify)
DMADOV (Define, Measure, Analyze, Design, Optimize and Verify)
DMEDI (Define, Measure, Explore, Develop and Implement)
IDOV (Identify, Design, Optimize and validate)
IIDOV (Invent, Innovate, Develop, Optimize and validate)
3. Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
www.iosrjournals.org 98 | Page
DMAIC methodology has been used as effective methodology in before mentioned organization;
details of this methodology are given as.
2.5. Define, Measure, Analyze, Improve and Control (DMAIC)
Basically this methodology comprises of following five key points.
Define the process improvement goals that are aligned with the customer demands and company’s strategy.
Measure the current process and make a strategy for making further improvement.
Analyze to verify the relationship and causality of factors. Determine what the relationship is and attempts
to ensure that all the factors have been considered.
Improve and optimize process based on findings of analysis phase using different techniques.
Control to ensure that any variances are corrected before they result in defects.
2.6. DMAIC Implementation at Pump Casing manufacturing company
DMAIC is chosen as potential methodology for implementation at pump casings manufacturing
company. At this company quality management systems like ISO 9000 are already implemented that’s why
quality improvement focus is to only reduce nonconformities. Figure 1 describes the five phases of DMIAC that
are implemented at manufacturing facility with different statistical techniques.
Define Phase
Problem description, project goal and
charter, communication plan, process
flow chart, SIPOC, Defining customer
and process requirements, Pareto chart,
Voice of customer (VOC), Critical to
quality tree (CTQ)
Measure Phase
X bar and R chart to analyze process
before improvement, calculating process
mean, standard deviation, cumulative
distribution function and sigma
capability, other analysis include Cause
and effect matrix for rotor casing
assembly, Measurement system
Analysis (MSA), Gage R&R study and
its Analysis of Variance
Analyze Phase One Sample Z test for average cylinder
inner diameter, Multi Variant Analysis,
Analysis of Variance (ANOVA)
Improve Phase
Multi-level factorial design, Main effect
and interaction effect analysis of factors,
Regression Analysis, Analysis of effect
Achieved after improvement, One
sample z-test and two sample
T-test Analysis
Control Phase Potential problem Analysis, Overall
Control Plan, Sample process control
plan, Project Conclusion
Figure 1. DMAIC Flow Chart
III. Define Phase
It is the first stage of Six Sigma DMAIC project, the phase determines the objectives and scope of the
project and it defines the problem & communicates the problem to others.
3.1. Problem Description
Company ABC is a manufacturing organization that produces pump casings and different sub-
assemblies related to Pump. For the few weeks company is receiving high rejection rate in pump casings, this
results in high rework rate and due to which higher production time is spent and also credibility of the company
and profits are being affected.
Approximately 25% pump casings produced by manufacturing facility are either required to be
reworked or rejected at final inspection (Rework and rejection are both considered as defects), this was found
when the last two lots were sampled for inspection.
4. Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
www.iosrjournals.org 99 | Page
3.2. Project Goal and Charter
Management of the company wanted a detail process study of different sections of manufacturing
Facility. For this purpose a project team was made whose primary responsibility was to identify the key factors
playing role in rejection and rework and then to take certain improvement measures to reduce the rejection rate.
Table 1 clearly defines the Project Team Charter. Clearly the project goal is to reduce Current rejection rate
from 25% to 1% (acceptance limit).
Table 1. Project Team Description
3.3. Communication Plan for DMAIC Project
Table 2 shows the complete communication plan for Project.
Table 2. Communication Plan for Six Sigma Project
3.4. SIPOC for Pump Casings
Supplier, Inputs, Processes, Outputs, Customers i.e. SIPOC is a process improvement and analysis tool
that summarizes the input and output of one or more processes. This tool helps to sum up the inputs and outputs
of a certain process according to the customer point of view that helps to analyze the requirements of each
process in one table format.
For the current facility the SIPOC is shown in Table 3. From the current system study it was revealed
that Pump casings key supplier is material store accompanied with manufacturing shops. Inputs to the process
are manufacturing process parameters and piece of bars in rectangular and cylindrical form. Complete process
details and outputs along with customers are shown in Table 3.
Project Team Charter
Team Members Status Involvement in Project
Sponsor and Champion Define, Project Charter,
Project Closure
Black Belt Project Implementation
Production Department Improve and Control
Quality control Head Data collection and Analysis
Project Title: Implementation of Six Sigma to reduce rejection
rate of Pump Casings.
Subject Matter Experts: Black Belt, Champion Six Sigma.
Stake Holders: Employees of Company, Production
Department, and quality control Department.
Project Milestones
S.NO. PHASE
1 Define
2 Measure
3 Analyze
4 Improve
5 Control
What To
whom
When Who How Where
Project
meetings
Project
team
invitees
Every
Thursday
Black
belt
Via
mail
Conference
room
Minutes of
meetings
Distribu
tion list
Next day of
meeting
Black
belt
Via
mail
Office of black
belt
Team work Project
team
As per
requiremen
t
Black
Belt
Via
mail
Office of black
belt
Status reports Custom
er
Every
Friday
Black
Belt
Via
mail
Office of black
belt
5. Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
www.iosrjournals.org 100 | Page
Table 3. SIPOC for Pump Casing
3.5. Process flow chart for Pump casings
Complete flow chart of the manufacturing process at manufacturing facility of pump casings was
developed and shown in Figure 2. This chart provides good understanding of process and material flow.
Figure 2. Pump Casing’s Process Flow Chart
3.6. Defining Process boundaries and customer Rrequirements
Main manufacturing processes are setup to process three items named as cover, cylinder and pads.
Complete flow diagram is illustrated in Figure 3. According to detailed study of the processes it was revealed
that chamber inner diameter, nozzle throat diameter and some other defects were contributing to high
nonconformance rate . Figure 3 shows a Pareto chart which summarizes the key defects in process outputs, this
show that chamber Inner Diameter accounts for 71.4% of total defects and comes to be potential Key Process
Input Variables (KPIV) to be addressed.
Suppliers Inputs Processes Outputs Customers
Material
store
Welding
section,
Milling
section,
Turning
section,
Drilling
section
Piece of round/
rectangular bar,
Tool angle,
Tool,
Feed,
Depth of cut,
Coolant flow
Facing,
Turning,
Taper turning,
Boring,
Threading,
Milling,
Drilling,
Welding,
Assembly.
Rotor cylinder,
Pads with holes,
Padded Rotor
cylinder,
Nozzle end,
Front Stopper,
Chuck
Ring,
Hexagonal
section of nozzle
end,
Assembled rotor
casings
Inspection and
quality
department,
Assembly
section,
Manufacturing
shops,
End users
6. Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
www.iosrjournals.org 101 | Page
Figure 3. Pareto chart for defects monitoring
Customer data i.e. Voice of Customer (VOC) revealed that internal customers are being affected by the
defects rate of Chamber inner diameter that accounts for major portion of defects as explained in Figure 3. Thus
Critical To Quality (CTQ) tree can be established based on voice of customer and project objectives. Figure 4
shows the CTQ tree based on the voice of customer
Figure 4. Critical To Quality (CTQ) Tree
IV. Measure Phase
The primary requirement of this phase is the complete process map of manufacturing process that is
given in Figure 2 of define phase. Measure Phase focuses on the following points about Six Sigma Project.
4.1. Determines What to Measure
The Six Sigma project team needs to come out with an explicit list of vital inputs, desired outputs and
process metrics that they are planning to track. This decision has large scale implications on the performance of
the project and is usually taken by the Project Leader on the basis of data provided by the Six Sigma team and
the Process Owner.
4.1.1. Determine How to Measure
There have been many cases of measurement bias in Six Sigma history. The bias may have its roots in
the complexity of the calculation, the wrong method of data collection or the bias of the person performing the
exercise.
4.1.2. Manage the Measurement Process
One of the biggest challenges of this phase is to validate the fact that the measurement system in place
is good for the purpose. This challenge has been discussed in detail in the section titled Measurement Systems
Analysis.
7. Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
www.iosrjournals.org 102 | Page
4.1.3. Calculating the Current Sigma Levels
A common practice in the measure phase is to put a figure in front of the losses that the organization is
currently facing due to inefficient processes. This helps the management to evaluate the process and the Six
Sigma team can bargain for more resources to successfully implement the project.
4.2. Current Base line for the Process
Mean of cylinder inner diameter = 50.4512mm
Standard deviation = 0.0708445mm
Upper specification limit = 50.6 mm
lower specification limit = 50.4 mm
4.2.1 Cumulative Ddistribution Function of sample taken
Normal with mean =50.4512mm and standard deviation = 0.0708445mm.
Cumulative Distribution Function
x P(X<=x)
50.4 0.234929
50.6 0.982152
4.2.2. Defective parts per million opportunities (DPPMO)
Equation 2 gives us the formula to calculate defective parts per million opportunities.
DPPMO = (% of parts less than 50.4) + (%of parts greater than 50.6)/1, 000000 (2)
Using Equation 2 the defect percentage is calculated as.
= (0.234929) + (1-0.982152)/1000000
= 252,777
= 25.27%
4.2.3. Inverse Cumulative Distribution function
Normal with mean = 0 and standard deviation = 1
Inverse Cumulative Distribution Function
P(X<=x) x
0.252777 -0.665776
Measure of distance from the mean of sample (Z-score) is calculated to be = 0.665776
Process Capability index (Cpk) is calculated to be
= 0.665776/3
= 0.2219
Sigma capability = Z-score + 1.5 (3)
Using equation 3 sigma capability for current process before improvement is calculated to be = 2.16
4.3. Cause and Effect matrix for Pump casing Assembly
Cause and effect matrix for pump casings was made in detail and relationship between process inputs
and outputs is described. From Table 4 it is clear that depth of cut, feed rate and tool angle are the important
factors affecting the quality of pump casings.
8. Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
www.iosrjournals.org 103 | Page
Table 4. Cause and Effect Matrix (C&E)
Where A= cylinder length, B= cylinder inner diameter, C = cylinder wall thickness, D = cylinder front prepped,
E = cylinder rear prepped, F = Nozzle throat Diameter, G = D-Nozzle Outer diameter, H = D-Nozzle angle.
4.4. Measurement System Analysis [MSA]
The next step in measurement phase is measurement system analysis. Basic measurement tool is
Venire caliper. Two measurement analysis techniques named Gage Linearity and bias Study and Gage R and r
study were used and details are given.
4.4.1. Control Charts
In statistical process control XBar and R charts are type of control charts that are used to monitor
samples data when data is collected at different intervals. Usually standard Deviations are monitored by Range
chart commonly known as R chart and sample mean is monitored by X-bar chart.
In Figure 5 the XBar-R chart shows that process is out of control with maximum observations out of
limits. Also a certain pattern is followed by the data points which may be due to machine error or operators shift
change. Reasons of out of Control manufacturing process are given in Analyze Phase of the Project.
Rating of
Iimportance to
Customers
7 8 8 7 7 9 9 9
S/N 1 2 3 4 5 6 7 8
Process output
Process
input
A B C D E F G H Total
Depth of cut 9 9 9 9 9 9 9 9 576
Feed 0 0 3 3 3 3 3 3 147
Tool Angle 1 3 1 3 3 3 1 3 144
Tool 1 3 1 1 1 3 1 1 98
Speed 1 1 1 3 3 1 1 1 92
Coolant Flow 0 1 1 1 1 3 1 1 75
Material Type 1 1 1 1 1 1 1 1 64
Figure 5. Xbar-R chart of cylinder inner Diameter before improvement
9. Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
www.iosrjournals.org 104 | Page
Table 5. Gage Linearity Analysis
Predictor Coefficient SE Coefficient P
Constant 0.01434 0.01442 0.324
Slope 0.0000145 0.0001223 0.906
S 0.070711 R-sq 0.0%
Linearity 0.0000051 %Linearity 0.0
Table 6. Gage Biasness Analysis
Reference Bias %Bias P
Average 0.0156667 4.4 0.017
1.5 -0.031666 8.9 0.445
25 0.0675000 19.1 0.004
80 0.0125000 3.5 0.006
150 0.0216667 6.1 0.012
200 0.0083333 2.4 0.001
Results shown in Table 5 and 6 provides enough evidence that bias of the instrument is constant over
its measuring range and the gage measures constantly regardless of the part size.
4.5. Gage Repeatability and Reproduce ability (R&R) Study-ANOVA Method
Another study of the measurement system was made by analysis of variance of gage. Complete data of
the analysis is Table 7 and 8.
Table 7. Two-Way ANOVA Table with Interaction
Source DF SS MS F P
Part ID 9 1.4244 0.158271 2347.9 0.00
Operator 1 0.00003 0.0000 0.4 0.54
Part ID*Operator 9 0.00061 0.000067 2.25 0.03
Repeatability 40 0.0012 0.000030
Total 59 1.42627
Table 8. Gage R&R Analysis
Source VarComp %Contribution (Varcomp)
Total Gage R&R 0.0000425 0.16
Repeatability 0.0000300 0.11
Reproducibility 0.0000125 0.05
Operator 0.000000 0.00
Operator*Part ID 0.0000125 0.05
Part-To-Part 0.0263673 99.84
Total Variation 0.0264098 100.0
Source St Dev Study %study Tolerance
Variation Variation
Total Gage R&R 0.006517 0.033562 4.01 6.71
Repeatability S 0.005477 0.028208 3.37 5.64
Reproducibility 0.003531 0.018186 2.17 3.64
Operator 0.00000 0.00000 0.0 0.00
Operator*Part ID 0.003531 0.018186 2.17 3.64
Part-To-Part 0.16238 0.836257 99.92 167.25
Total Variation 0.162511 0.836931 100.0 167.39
No. of Distinct Categories = 35
10. Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
www.iosrjournals.org 105 | Page
Figure 6. Gage R&R (ANOVA) for Measurement
By the complete ANOVA study and Gages run chart and R&R chart analysis shown in Figure 6 it is
clear that percentage contribution of repeatability and reproducibility is very minimum and these are not making
significant impact in variation data. Main cause of variation is found to be part to part variation.
Figure 7. Multi-Vari Chart for Cylinder Inner Diameter by Depth of Cut-Tool Angle
11. Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
www.iosrjournals.org 106 | Page
By Table 8 it is clear that Measurement Gage
%contribution is 0.16<1,
%study variation = 4.01 < 10%,
%Tolerance = 6.71 < 10%,
%Distinct categories = 35>10
Hence the measurement system is acceptable and reliable for measurement purpose.
V. Analyze Phase
This phase focuses on analyzing the cause of defects defined in the before mentioned project phases.
The first analysis was made on cylinder inner diameter. Table 9 shows One sample z test performed to check
whether average inner cylinder diameter was 50.4512 or not.
Table 9. One-sample Z-Test of Cylinder inner diameter.
Factor Type Levels Values
Depth random 3 1.0, 1.5, 2.0
Of cut
Feed random 3 8,9,10
Tool angle random 3 25, 30, 35
Source DF SS MS F P
Depth of cut 2 0.015528 0.0077 14.23 0.00
Feed 2 0.005140 0.0002 0.470 0.62
Tool angle 2 0.162343 0.08117 148.75 0.00
Error 74 0.040380 0.00054
Total 80 0.287650
S = 0.0233598 R-sq. = 81.54 % R-sq. (adj.) = 80.05%
As given in Table 9 the P-Value of 1 is greater than alpha = 0.05, the decision is not to reject null
hypothesis. There is strong evidence that the average cylinder inner diameter is 50.4512 mm. Next in the
analyze phase is Multi-vari Analysis that was performed with three variables i.e. depth of cut with three settings
1.0,1.5,2.and tool angle with settings 25,30,35 degrees and feed rate with settings 8,9 and 10mm per minute.
Figure 7 shows the Analysis. The settings of variable that gave best responses are
Depth of cut = 1 mm
Feed = 8 mm/min
Tool angle = 35 degrees
Next in the analyze phase is ANOVA performed on cylinder inner Diameter versus Depth of cut, Feed,
Tool Angle. Exhibit Table 10 shows complete Analysis data.
Table 10. Analysis of Variance of Cylinder Inner Diameter
Factors 2 Replicates: 3
Base runs 9 total runs 27
Base blocks1 Total Blocks 1
Number of levels: 3, 3
Factor Type Levels Values
Depth of Cut fixed 3 1.0, 1.5, 2.0
Tool angle fixed 3 25, 30, 35
Source DF AdjSS Adj MS F P
Depth of cut 2 0.01111 0.00555 11.2 0.001
Tool angle 2 0.073563 0.036781 74.11 0.626
Tool angle* 4 0.010148 0.000253 5.11 0.006
Depth of cut
12. Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
www.iosrjournals.org 107 | Page
Error 18 0.008933 0.000496
Total 26 0.103763
S = 0.0222777 R-sq. = 91.39% R-sq. (adj) = 87.56%
From data given in Table 10 it is clear that depth of cut and tool angle has significant effect over the
response variable whereas feed has no significant effect. Hence these variables were considered in the improve
phase for improving the response variables.
VI. Improve Phase
Key findings from the analyze phase are that depth of cut and tool angle have the significant effect on
the cylinder inner diameter. This was further analyzed by Multilevel factorial design in Table 11 in which
cylinder inner diameter was tested against different levels of tool angle and depth of cut data obtained is given
in Table 11.
Table 11. Analysis of variance of Cylinder Inner
Diameter using adjusted SS for tests
Factors 2 Replicates: 3
Base runs 9 total runs 27
Base blocks1 Total Blocks 1
Number of levels: 3, 3
Factor Type Levels Values
Depth of Cut fixed 3 1.0, 1.5, 2.0
Tool angle fixed 3 25, 30, 35
Source DF AdjSS Adj MS F P
Depth of cut 2 0.01111 0.00555 11.2 0.001
Tool angle 2 0.073563 0.036781 74.11 0.626
Tool angle* 4 0.010148 0.000253 5.11 0.006
Depth of cut
Error 18 0.008933 0.000496
Total 26 0.103763
S = 0.0222777 R-sq. = 91.39% R-sq. (adj) = 87.56%
Figure 8. Main Effect Plots for Cylinder Inner Diameter
13. Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
www.iosrjournals.org 108 | Page
Figure 9. Interaction Plot (Data Means) for Cylinder Inner Diameter
Figure 8 and 9 show the main effect and interaction effect of depth of cut and tool angles. Form plots it
is clear that depth of cut, and the interaction have significant effect on the response variable best results are
obtained for the settings:
Depth of cut = 1.5 mm
Tool angle= 30 degrees
Regression analysis was also made to get the correlation between different response variables. The
regression equation is given by equation 4.
Cylinder inner diameter = 50.1 + 0.0058* depth of cut + 0.126 *Tool angle (4)
Table 12. Multiple Regression Analysis
Predictor Coef SE Coef T P
Constant 50.0974 0.042 1192.23 0.00
Depth of cut 0.00583 0.01244 0.47 0.642
Tool angle 0.01258 0.001244 10.12 0.000
S = 0.0304622 R-sq. = 75.7% R-sq. (adj) = 74.2%
Table 13. Analysis of variance (ANOVA)
Source DF SS MS F P
Regression 2 0.095528 0.047764 51.3 0.000
Residual 33 0.030622 0.000957
Error
Total 35 0.125831
Using the multiple regression analysis in Table 12 and 13 it is clear that tool angle has significant
effect on response variable whereas depth of cut has also an effect but not to significant. This is further
confirmed by the best subset regression considering the maximum r-sq and minimum mallows c-p criteria, tool
angle has the most effect and the interaction has the significant effect on the second number. The settings
obtained from the analyze phase were implemented and data was monitored for some time.
6.1. Analysis of the effect achieved after improvement
Mean of cylinder inner diameter = 50.4972mm
Standard deviation of cylinder inner diameter= 0.032479mm
14. Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
www.iosrjournals.org 109 | Page
6.1.1. Cumulative distribution function of sample taken
Normal with mean =50.4972mm
Sstandard deviation = 0.0324795mm
Cumulative distribution function
x P(X<=x)
50.4 0.001383
50.6 0.999225
6.1.2. Defective parts per million opportunities (DPPMO)
Using formula given in equation 2, DPPMO is given as
= (0.001383) + (1-0.999225)/1000000
= 2,158
= 2.158%
6.1.3. Inverse Cumulative Distribution function
Normal with mean = 0mm and standard deviation = 1mm
P(X<=x) x
0.002158 -2.85409
Measure of distance from the mean of sample (Z-score) is calculated to be Z-score = 2.85409
Process Capability index (Cpk) is calculated to be
Cpk = 2.85409/3 = 0.951363
Using equation 3, Sigma capability for current process before improvement is calculated to be
Sigma capability = Z-score + 1.5
= 2.85409 +1.5
= 4.354
6.2. Ensuring the sampling errors with test of Hypothesis
To ensure that average cylinder inner diameter is 50.4972 or not a one sample Z test was performed.
Exhibit 23 shows findings as follows:
Ho: µ=50.4972 (claim) and
H1: µ≠50.4972
Table 14. One-sample Z: Cylinder Iinner diameter
Test of mu = 50.4972 vs. not = 50.4972
The assumed standard deviation = 0.0324795
Variable N mean stdev SE Mean 95%CI Z P
Cylinder 36 50.49 0.03 0.0054 (50.48, 0.0 0.9
inner D 50.50)
As given in Table 14 the P-value of 0.997 is greater than α = 0.05 the decision here is not to reject the
null hypothesis. there is enough evidence to support the claim that the average cylinder inner diameter is
50.4972.
6.3. Testing difference between two Means (Large independent systems)
Ho: µ1 = µ2 and
H1: µ1 ≠ µ2 (claim)
6.3.1. Two sample T-Test and CI: Cylinder inner diameter
Table 15 shows test results.
15. Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
www.iosrjournals.org 110 | Page
Table 15. Two sample T-Test
N Mean StDev SEMean
Cylinder Inner D 50 50.4512 0.0708 0.010
Cylinder Inner D 36 50.4972 0.0325 0.0054
Difference =
mu (cylinder inner Dia. Before Imp) – (Cylinder Inner Dia. After Imp)
Estimate of difference : -0.046022
95% CI for difference : (-0.068718, -0.023326)
T-Test of difference = 0 (vs. not =): T-Value = -4.04
P-Value = 0.000, DF=73.
In Table 15 the P value of 0.00 is less than alpha=0.05 so the decision is to reject the null hypothesis.
There is enough evidence to support the claim that the two means are not equal. There is significant difference
in cylinder inner diameter before and after process improvement.
VII. Control Phase
Tables 16 and 17 show the overall control plan for the Project. Overall control plan includes three
phases. First one is solution implementation Phase, in this phase settings of DMAIC Implementation phase were
carried and observed for 2 months and were communicated to Project sponsor, process owner and Quality
control head. Main objective of this phase is to monitor the process and decide whether the process is settled
down and has absorbed the changes by giving the required results or it does not continue to give the improved
results because of some other factors setting’s that might be overlooked in the Improve Phase.
Next is training Phase which includes training of working staff as well as process owners and Quality
Head to make them able to provide improved results if working conditions are slightly changed e.g. induction of
new Machine in Assembly line or workers shift changes etc. Cost and benefits analysis is the last and project
conclusion Phase, that was done after solution was Implemented and observed for 2 months.
Process Control plan is given in Table 17. It includes control of Pump Casings Inner diameter boring Control.
Machine used is turning and 100% inspection was carried on to observe this Process In detail. XBar
and R charts were used to observe processes deviation and Mean shifts.
By observing XBar-R chart in Figure 10 it is clear that the process is well in control i.e. the variation
with in groups is controlled. There are no points in X-bar chart that are more than 3 standard deviation away
from Process Mean, also R chart shows that variation of process is well under control.
Table 16. Overall control plan
S/No. Description Communicated to Approximate duration
1. Solution
implementation
schedule
Sponsor,
process owner,
Qc head
02 months
2. Training Process owner, Qc head 02 weeks
3. Cost and Benefits
Analysis
Sponsor Was carried Out after Implementing the solution and
running the process for 2 months
Table 17. Sample process control plan
Process/
operation
description
Machine
Jigs, tools,
Fixtures for
manufacturing
Methods
Category Number Spec.
limit
Sample
size
Control
method
Inner
Dia.
Boring
Turning Jig T/jig/
002
100%
inspect
ion
5 X-bar,
R-charts
16. Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
www.iosrjournals.org 111 | Page
Fig.10. XBar-R chart of cylinder inner Diameter after improvement
VIII. Conclusion
Local pump casing manufacturing facility was receiving high defect rate due to which quality of the
production lots was being effected and customer complaints had to be addressed. This was turning in to high
financial loses to the company. An effective quality improvement technique called Six Sigma was decided to be
implemented in the facility.
At this stage the defect rate was 25.27% with sigma capability of 2.16. Pareto charts defined that
chamber inner diameter defects were more than 71.4% of the total defects and was potential KPIV to be
addressed. Further analyses cleared that depth of cut; feed rate and tool angle were contributing in defect rate.
After carrying out detailed analysis of the process ,tool settings came out as main reason for this defect rate.
feed rate had not significant effect as compared to depth of cut and tool angle. Best results were achieved at:
Feed rate = 8mm/min
Depth of cut = 1.5 mm
Tool angle = 30 degrees
Some jigs and fixture were required to achieve the above settings during production of rotor casings.
These were designed and manufactured and then were Incorporated to reduce setups times and eliminate
adjustments.
After getting the right settings from the analyze phase these settings were implemented and results
achieved were in favor of good quality of products. Further results were monitored and controlled and finally
defect rate observed is 2.158% with sigma capability of 4.354.
References
[1]. Douglas, C. M. (2003). Introduction to Statistical Quality Control. New York, NY: John Wiley Publications.
[2]. Mahesh, B. P., Prabhuswamy, M. S. (2010). Process Variability Reduction through Statistical Process Control for Quality
Improvement. International Journal for Quality research, 4(3), 1621-1635.
[3]. James, M. J., Mary, E. J. (2006). Lean and Six Sigma. LABMEDICINE, 37(3), 407-408.
[4]. John, J. F., Clark, W. A., San, C. A. (2006). Selecting Optimal Specification Limits. Quality Technology & Quantitative
Management, 3(2), 207-216.
[5]. Pleck, A., Vjica, H. (2009). An Application of six sigma in manufacturing company. Advances in production engineering and
Management, 4, 243-254.
[6]. John, J. F. (2009). A unifying process capability metric. JIEM, 2(1), 48-59.
[7]. Mahesh, B. P., Prabhuswamy, M. S. (2010). Improvement of Quality Awareness using Six Sigma methodology for achieving
higher CMMI Level. International journal of advance research in management, 1(1), 20-41.
[8]. Alessandro, L., Jiju, A., Alex, D. (2010). Lean six sigma in a call center: a case study. International Journal of Productivity and
Performance Management, 59(8), 757-768.
[9]. Richard, J. L., Fugee, T., Lau, W. C. (2006). Supplier Selection Based on Process Capability and Price. Quality Engineering, 18,
123–129.
[10]. Charles, R. Theodore, T. A. (2003). An Alternative Desirability Function for Achieving Six Sigma Quality. Quality and Reliability
Engineering, 19, 227–240.
[11]. Chen, K. S., Huang, M. L., Li, R. K. (2001). Process capability analysis for an entire product. International Journal of Production
Research, 39(17), 407-408.
[12]. Van, D. H., Edwin, R., Ion, S., Roxana, A. (2003). Control chart for Markov Dependent Sample Size. Quality Engineering, 12(4),
593-601.
[13]. Jeroen, D. M., Kit, C. B., Ronald, J. M. (2001). The multi vary chart: A systematic approach. Quality Engineering, 13(3), 437-439.
17. Six Sigma Implementation to reduce rejection rate of Pump Casings at local Manufacturing Company
www.iosrjournals.org 112 | Page
Author’s Biographies
Faheem Yousaf is Masters Student at National University of Science and Technology in the School of
Mechanical and Manufacturing Engineering. He received his Bachelor’s degree in Industrial Engineering from
University of Engineering and Technology Pakistan. His research interests include Quality Management,
Operation Management and Manufacturing Engineering.
Shahid Ikramullah Butt, PhD, is Head of Mechanical Engineering at National University of Science
and Technology in the School of Mechanical and Manufacturing Engineering. He has fifteen years of Industrial
and Teaching Experience with different Organizations. Dr. Shahid received his Masters degree in Industrial
Engineering from Mississippi State University and later on got his PhD. in industrial and manufacturing
engineering from Beijing Institute of technology, China.
Riaz Ahmad, PhD, is acting as director research at National University of Science and Technology.
He has blend of industry and academic experience spanning over 27 years. Besides being at senior management
posts at university, he is supervising research and teaching undergraduate and post graduate courses at
university. He has published number of research papers in international journals and conferences in field of
Mechanical Engineering.
Contact: Faheem Yousaf, School Of Mechanical and Manufacturing Engineering, National University
of Science and Technology, Islamabad, Pakistan, Engr_faheem37@yahoomail.com.