Mittal Ankesh, Gupta Pardeep, Kumar Vimal, Al Owad Ali, Mahlawat Seema, Singh Sumanjeet
Department of Mechanical Engineering, Sant Longowal Institute of Engineering & Technology, Longowal, Punjab, India.
Department of Information Management, Chaoyang University of Technology, Taichung, Taiwan.
Heliyon. 2023 Mar 18;9(3):e14625. doi: 10.1016/j.heliyon.2023.e14625. eCollection 2023 Mar.
The six-sigma methodology has been adopted by the industry as a business management tool to improve operational capabilities and reduce defects in any process. This study aims to present a case study on the implementation of the Six-Sigma DMAIC methodology with the purpose to reduce the rejection rate of rubber weather strips manufactured by XYZ Ltd. (name changed) situated in Gurugram, India. Weather strips are used in all four doors of cars for noise reduction, waterproofing, dust proofing, soundproofing, windproofing, and for improving air conditioning cooling, and heating effects. The overall rejection rate of both front and rear door rubber weather strips was 5.5% which was causing a huge loss to the company. The average rejection rate of rubber weather strips per day reduced from 5.5% to 3.08%. After implementing the Six-Sigma project findings the rejection was reduced from 153 pieces to 68 pieces helped the industry in saving the cost of a compound by Rs. 15,249 per month. The sigma level improved from 3.9 to 4.45 within three months with the implementation of one Six-Sigma project solution. The company was highly concerned about reducing the high rejection rate of rubber weather strips and decided to deploy Six Sigma DMAIC as a quality improvement tool. The industry was keen to reduce this high rejection rate to 2% and this target was materialized with the application of the Six-Sigma DMAIC methodology. The novelty of this study is to analyze performance improvement considering the Six Sigma DMAIC methodology to reduce the rejection rate of rubber weather strip manufacturing companies.
六西格玛方法已被行业用作一种业务管理工具，以提高运营能力并减少任何流程中的缺陷。本研究旨在呈现一个关于实施六西格玛DMAIC方法的案例研究，目的是降低位于印度古鲁格拉姆的XYZ有限公司（名称已更改）生产的橡胶挡风雨条的拒收率。挡风雨条用于汽车的所有四个车门，以降低噪音、防水、防尘、隔音、防风，并改善空调的制冷和制热效果。前后车门橡胶挡风雨条的总体拒收率为5.5%，这给公司造成了巨大损失。橡胶挡风雨条的日均拒收率从5.5%降至3.08%。实施六西格玛项目成果后，拒收数量从153件减少到68件，帮助该行业每月节省了15,249卢比的复合材料成本。通过实施一个六西格玛项目解决方案，西格玛水平在三个月内从3.9提高到了4.45。该公司高度关注降低橡胶挡风雨条的高拒收率，并决定采用六西格玛DMAIC作为质量改进工具。该行业渴望将这种高拒收率降低到2%，而这一目标通过应用六西格玛DMAIC方法得以实现。本研究的新颖之处在于考虑六西格玛DMAIC方法来分析性能改进，以降低橡胶挡风雨条制造公司的拒收率。
