Application of Six Sigma DMAIC framework to reduce the rejection IN the PERSONAL care product manufacturing Unit: A case study
DOI:
https://doi.org/10.69980/2dv6zf57Keywords:
Six Sigma, DMAIC, Cause and Effect Matrix, FMEA, 4MAbstract
In a rapidly changing and highly competitive environment, each Organization is striving to deliver better quality products & services to the customer. To meet the required Quality standards, organisations work hard to reduce all variations and make the production process optimal. Six Sigma methodologies are widely being implemented by almost all core sectors e.g. Manufacturing, Healthcare, Banking, Education, Hospitality, Agriculture, Aviation, and even some of the government-allied sectors. The prime objective of “Six Sigma methodology” is to minimize “process variations”; however it results in numerous tangible benefits like enhancing the Quality of the products/services, reducing the production / operational costs, increasing profitability, minimizing the turnaround time of processes, variations, and most importantly enhancing customer satisfaction This case study is based on one of the most important Six Sigma frameworks called “DMAIC”. The DMAIC method was implemented to identify and analyse various causes of higher rejection percentages during the production of a new product in the personal care product manufacturing unit. The “higher rejection” issue was not only resulting in financial loss but also impacting timely deliveries and the Customer satisfaction index. Therefore, the Six Sigma DMAIC (Define, Measure, Analyse, Improve, Control) approach was adopted, which helped in reducing rejection from 6.1% (Jan’24) to 3.1% (April’24). Consequently, it resulted in considerable cost savings, improves Product delivery compliance and eliminated the probability of getting consumer complaints due to quality defects.
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