Table of Contents
Journal of Quality and Reliability Engineering
Volume 2013 (2013), Article ID 752164, 13 pages
http://dx.doi.org/10.1155/2013/752164
Research Article

Productivity Improvement of a Special Purpose Machine Using DMAIC Principles: A Case Study

1Department of Mechanical Engineering, PVPIT, Bavdhan, Pune, Maharashtra 411021, India
2Mechanical Engineering, PVPIT, Bavdhan, Pune, Maharashtra 411021, India
3Department of Mechanical Engineering, JDIET, Yavatmal, Maharashtra 445001, India

Received 5 April 2013; Revised 16 July 2013; Accepted 22 July 2013

Academic Editor: Shey-Huei Sheu

Copyright © 2013 Sunil Dambhare et al. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

Abstract

Six Sigma is one of the popular methodologies used by the companies to improve the quality and productivity. It uses a detailed analysis of the process to determine the causes of the problem and proposes a successful improvement. Various approaches are adopted while following Six Sigma methodologies and one of them is DMAIC. The successful implementation of DMAIC and FTA is discussed in this paper. In this study, the major problem was of continuous rework up to 16%, which was leading to wastage of man hours and labor cost. Initially, fault tree analysis (FTA) was used to detect the key process input variables (KPIVs) affecting the output. Multivariable regression analysis was performed to know the possible relationship between the KPIVs and the output. The DMAIC methodology was successfully implemented to reduce the rework from 16% bores per month to 2.20% bores per month. The other problem of nonuniform step bores was also reduced significantly.