WRAP THE SCRAP WITH DMAIC: Strategic Deployment of Six Sigma in Indian Foundry SMEs
(Sprache: Englisch)
Six Sigma approach is generally employed to improve the sigma level of manufacturing or service processes by reducing their deviations and defects. Six Sigma provides the opportunity to eliminate mistakes, improve morale and save money. Doing things right...
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Six Sigma approach is generally employed to improve the sigma level of manufacturing or service processes by reducing their deviations and defects. Six Sigma provides the opportunity to eliminate mistakes, improve morale and save money. Doing things right in first time and keeping them consistent is the only idea behind Six Sigma. Its fundamental objective is to achieve customer satisfaction with continuous improvement in quality and productivity. Mostly we are emphasizing on various tools or techniques being used during DMAIC projects and almost ignore the procedure to execute different phases of the Six Sigma project. This book provides unique step by step methodologies to perform Define, Measure, Analyse, Improve and Control phases of a Six Sigma project, respectively. An empirical investigation has been carried out in a make-to-order type (medium sized) foundry and Six Sigma is successfully implemented by decreasing the scrap of piston castings, appreciably. The book focuses on scrap reduction specifically in Indian foundries and tries to find out the reasons of low productivity index. It also tends to shatter the various phobias of SMEs in context of Six Sigma by validating the compatibility of proposed methodologies through a successful case study in Indian foundry environments.
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Chapter 1.1 PretextIn the present market, competitors are looking for flexibility and shorter production lead;times because only such a configuration of production system can fulfill the ever-changing;demands of customers (De Feo, 2000). But for this it is necessary to have less scrap as it is;well known that this will result into economic production (Wright and Basu, 2008). To;handle these challenges, companies are being forced to adopt such strategies/techniques;which can make production less costly and of optimum quality. Goh et al. (2004) highlights;that by scrap reduction, one can have maximum utilization of machines or equipments, which;will obviously enhance the production rate and make the overall production more feasible. So;for higher productivity, 'defect reduction' will be one of the most promising and viable;strategy and it will also help to cope up with the future challenges (Antony, 2002). To;achieve this efficacy, Six Sigma's DMAIC approach can be efficiently used in the given;production environments, particularly in foundry SMEs of India.;Over the past few decades, Six Sigma has been espoused successfully by many worldclass;companies. The main benefit of a Six Sigma program is the elimination of subjectivity;in decision-making by creating a system where everyone in the organization collects,;analyzes and displays data in a consistent way (Maleyeff and Kaminsky, 2002). Six Sigma is;regarded as a well-structured methodology for improving the quality of processes and;products. It helps to achieve the company's strategic goal through the effective use of;project-driven approach (Khan and Al-Darrab, 2010). Six Sigma projects must be linked with;business strategy and should meet the requirements of the customer (Singh & Khanduja,;2010a). Nowadays, Six Sigma has been widely adopted in a variety of industries in the world;and it has become one of the most important subjects of debate in quality management. Six;Sigma can help a company to achieve
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expected goals through continuous project;improvements.;Six Sigma is an established approach that seeks to identify and eliminate defects,;mistakes or failures in business processes or systems by focusing on those process;performance characteristics that are of critical importance to customers (Dulluri and;Raghavan, 2009). After more than two decades of successful implementation of Six Sigma; methodologies at major corporations, the benefits of Six Sigma are well documented now.;Although this strategy has been implemented with success in many large corporations, there;is still less documented evidence of ist implementation in smaller organizations, specifically;in foundries. Moreover, from literature survey it appears that foundries in India are still not;convinced that Six Sigma can be effectively implemented with their existing shop floor;constraints. This book attempts to address the issue: Can Six Sigma be effectively;implemented in Indian foundries? One of the common myths of Six Sigma that has emerged;over the last few years is that it is just applicable to large corporations with immense;resources and budget (Edgeman and Dugan, 2008). The purpose of this work is to test this;myth and to show that a Six Sigma based business strategy is applicable to all kinds of;foundries in developing countries (like India) irrespective of their size and type. The present;study has raised this serious issue and tried to formulate useful frameworks for each phase of;DMAIC methodology as far as Six Sigma implementation in Indian foundries is concerned.
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Autoren-Porträt von Bikram Jit Singh
Dr. BIKRAM JIT SINGH is working as a Professor in Mechanical Engineering Department of Maharishi Markandeshwar University, Sadopur, Ambala (Haryana). He is PhD. from National Institute of Technology, Kurukshetra on Six Sigma and has done Masters of Engineering with distinction in Industrial Engineering from Thapar University, Patiala. He has a three year Professional Experience as a Manager in Light Alloy Foundry at FEDRAL MOGUL, INDIA (A US based Multi-National at Bahadurgarh, India.). He was undergone on the job training on SAP (PP-Module), QS-9000, ISO-TS 16949, SQC Tools and TPM for 2 years. He had worked as Lecturer in Mechanical Engineering Department for Two Years at RIMT-Institute of Engineering & Technology, Mandi Gobindgarh, India. He was also posted as HOD-Mechanical at BBSBPC, Fatehgarh Sahib, India for One Year. He has around 15 International Journal publications along with paper presented in number of International and National Conferences. He is a main and corresponding Author and can be contacted at chann461@yahoo.com.Dr. DINESH KHANDUJA is a regular Professor from last 15 years at National Institute of Technology, Kurukshetra, India. Earlier he was posted as Assistant Professor in Regional Engineering College Kurukshetra. His fields of specializations are Industrial Engineering, Production Engineering and TQM. He had participated in more than 25 International and National Conferences and publishes around 38 Papers in various International and National Journals. He had also guided number of Master's and Doctorate students in the field of Six Sigma, Productivity Management, Waste Management and Entrepreneurship. He is also working as Head of Entrepreneurial Cell at NIT Kurukshetra India. He can be contacted at dineshkhanduja@yhaoo.com.
Bibliographische Angaben
- Autor: Bikram Jit Singh
- 2015, Erstauflage, 212 Seiten, Maße: 15,5 x 22 cm, Kartoniert (TB), Englisch
- Verlag: Anchor Academic Publishing
- ISBN-10: 3954893959
- ISBN-13: 9783954893959
Sprache:
Englisch
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