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Scrap Reduction in a Piston Manufacturing Industry:
An Analysis Using Six Sigma and DMAIC Methodology
--Dhiraj Kumar and Deepak Kaushish
Six Sigma at many organizations simply means a measure of quality that strives for near perfection. It is a disciplined data-driven approach and methodology for eliminating defects in any process, from manufacturing to transaction and from product to service. This paper demonstrates the empirical application of Six Sigma and DMAIC to reduce product scrap within a piston manufacturing organization. The paper follows the DMAIC methodology to investigate defects and root causes, and provides a solution to reduce/eliminate these defects. The analysis employing Six Sigma and DMAIC indicates that the design of casting spoon and its material influence the amount of defective pistons produced. In particular, the why-why analysis and two sample t-Test are combined to statistically determine the correlation of the casting spoon design and its material with defects as well as to define their optimum values needed to reduce/eliminate the defects. As a result, a reduction of scrap percentage from 9.9% to 5% was achieved, which helped the studied organization to reduce its Defects Per Million Opportunities (DPMO) from 99,000 to 50,000 and thus improve its Sigma level from 2.86 to 3.2. Also, the process yield was improved from 90.1% to 95% and a saving of 52 lakh/year was obtained. © 2015 IUP. All Rights Reserved.
Implementation of Lean Manufacturing in a Small-Scale Industry
--Pardeep Kumar and Sanjay Kajal
The purpose of the present paper is to implement lean manufacturing in a small-scale industry. In this regard, 5S tool is chosen for analysis in selected rice mills situated in Kurukshetra, Haryana. 5S weekly appraisal scores are calculated using 5S audit sheets, which show the adoption of lean manufacturing in the industry. The results reveal reduction in non-essential items such as tool searching time, dust, unwanted material and visual control. The results derived from the analysis were also discussed with the management who found the analysis to be very useful. © 2015 IUP. All Rights Reserved.
The Functional Integration of Operations Management in Banks:
A Framework for Research
--Thomas Ilin
This paper responds to emerging concerns from banking practitioners and media about service operations mismanagement in banking industry. It presents a general review, discussion and empirical analysis of relevant academic literature on cross-functional integration from the Service Operations Management (SOM) and Service Management (SM) domains, together with a proposed SOM functional integration framework for use in future research into the enterprise-wide cross-functional integration of operations management in banking. Empirical analysis of literature themes by industry, content analysis of key papers exploring their usage of the term ‘function’, and critical analysis of the literature from a new ‘functionalist’ perspective are conducted. The focus on strategic intentions in SOM and SM academic literature fails to address the emerging concerns in the banking industry regarding problems arising at functional execution levels of management. Research into this gap in knowledge may help to explain the factors contributing to banking performance shocks and their relationship to operational inadequacies exposed during economic turbulence. A functional integration framework provides banking operations managers with an improved ability to locate operational inadequacies, and thereby identify opportunities to increase operational resilience. Although the implications of this conceptual paper can be translated to the financial services industry in general, the examples presented here are from banking. © 2015 IUP. All Rights Reserved.
Case Study
Apple and Conflict Minerals: Ethical Sourcing for Sustainability
--Debapratim Purkayastha and Adapa Srinivasa Rao
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