Enhancement of sigma level in the manufacturing of furnace nozzle through DMAIC approach of Six Sigma: a case study

Abstract

In this paper, a case study on implementing Define, Measure, Analyze, Improve and Control (DMAIC) phases of Six Sigma programme in a furnace manufacturing company is reported. When Six Sigma was developed at Motorola, it was encapsulated with DMAIC and belt-based training infrastructure. Since belt-based training is expensive, companies with less revenue have been implementing only DMAIC phases. In this background, the impact of implementing DMAIC phases was examined in the research narrated in this paper through the reporting of the case study mentioned above. As the result of implementing DMAIC phases, the sigma level increased from 3.31 to 3.67 in the case of drilling a hole in a component called ‘furnace nozzle’. This increase in sigma level proved that DMAIC phases are powerful enough to enable the companies with less revenue to perform at six sigma level quality and acquire competitive strength.

Keywords:

• TQM
• Six Sigma
• DMAIC
• furnace manufacturing
• cause and effect diagram
• case study
• Pareto analysis