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The IUP Journal of Operations Management :
Role of DMAIC Approach in Manufacturing Unit: A Case Study
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Six Sigma is a management approach focusing on reducing waste by making small changes in the manufacturing system processes. The small manufacturing unit considered in this study was suffering from high rejection and low production rate. The main objective of the study is to reduce rejection rate and improve the quality by using DMAIC (Define, Measure, Analyze, Improve, and Control) cycle. The production pieces saved in five weeks after implementing DMAIC is 38.07% in pitting, 35.80% in total length undersize, 36.15% in un-filling, 45.93% in flash and 69.46% in bend defects. After implementation of DMAIC in forging process the rejection rate reduced to 1.88%.

 
 

Six Sigma can be considered both a business strategy and a science that has the aim of reducing manufacturing and service costs, and creating significant improvements in customer satisfaction and bottom line savings through combining statistical and business process methodologies into an integrated model of process, product and service improvement. In Six Sigma, customer focus becomes the top priority and any improvement is defined by their impact on customer satisfaction and value (Pande and Holpp, 2002). From an internal perspective, Six Sigma provides a way of improving processes so that the company can more efficiently and predictably produce world-class products and services. Traditionally under the Six Sigma approach a five-phased DMAIC (Define, Measure, Analyze, Improve, and Control) methodology is applied which tackles specific problems to reach Six Sigma levels of performance (Breyfogle, 1999).

 
 

Operations Management Journal,Management approach focusing, Manufacturing system processes,Role of DMAIC Approach in Manufacturing Unit.