Process Improvement in a Filter Manufacturing Industry through Six Sigma DMAIC Approach

Abstract

Six-sigma is a project oriented, statistical data driven, scientific approach which can be effectively deployed to tackle the issues like process variation, rejection and rework. During present study; Six-sigma methodology was utilized for rejection reduction of a manufacturing line at a filter manufacturing industry. This line was top contributor in plant’s PPM and COPQ. The defect PPM is a reflection for overall health of the manufacturing processes of organisation. Hence defect PPM is used as parameter to assess the Process Improvement and project effectiveness. Current project followed DMAIC approach. Initially, project objectives, scope, deliverables and constraints were defined. Then substantial data was collected to measure the current performance, process capabilities and PPM levels per defect. Significant root causes governing defect generation were identified through Cause and Effect, FMEA and Hypothesis testing. Thereafter, solutions were derived to mitigate the possibility of defect generation by process optimisation, mistake proofing and improvement actions. Finally various tools were implemented for tracking the process and maintaining it under control. The process variation, rework and scrap were reduced considerably as a result of current project. PPM level reduced to 6,500 from 24,000 corresponding rise in sigma level from about 3.43 to 4.02.