OENG1088 Integrating Six Sigma In A Manufacturing Process Case Study - Research Project

Background of Research

Six Sigma is simply a measurement technique that aims to make the quality of products and services be better. It is a data-driven methodology and approach that aims at eliminating the defects in the industrial processes from transactional to manufacturing and from services to products. Six Sigma uses statistical tools to fight the variability that a company may be experiencing. All companies usually experience variation thus making Six Sigma critical. It allows the reduction of the variability in the company to the lowest state possible. Most of the project teams have models that assist in the integration of the Six Sigma. The models are in the form of manuals or guides that help resolve a problem in a company based on variation. According to Gitlow and Levine (2005) the most common strategy or model that the project teams use is the Define, Measure, Analyse, Improve, and Control abbreviated as DMAIC. The methods are based on a guideline that enables the project team to know when and what statistical tools to use. It also enables the statistical and other tools used in a manufacturing company to understand the project priorities as per the effect and variation associated with the processes.

2.0 Current State-of-the-art

Companies such as Sony, Kodak, General Electric, and Motorola Solutions have integrated the Six Sigma. As a result, they have managed to convince their potential and current customers that any of their services or products that they provide is of good quality (Pillai, Pundir & Ganapathy 2012). The major disadvantage of Six Sigma is that the process can be completed only after the problems associated with the quality of products and services are solved. The solution of the problems can be achieved with the purchase of technology, machinery, tools, or a given amount of investment (Pacheco 2014). However, some of these issues might be complex for small businesses. Other challenges of integrating Six Sigma in the manufacturing process are due to its possibility to a suite in several projects. As a result, it is hard to determine which project should be given priority when integrating the Six Sigma. It is also hard to determine the project that will go through a significant change based on the desire to reduce variability (Hassan 2013). Companies that have a limited budget, therefore, need to take a lot of consideration before engaging in the integration of Six Sigma.

3.0 Research Objectives and Hypothesis

The research will be based on three main objectives;

1. To determine the suitable method that Six Sigma can be integrated into a manufacturing process
2. To analyse how Six Sigma can be deployed in Constraints Management for the improvement of manufacturing companies
3. To evaluate how Sigma Six can be integrated into manufacturing companies with limited resources

The research questions for the study will, therefore, be

1. What are the suitable methods to which Six Sigma can be integrated into the manufacturing process?
2. How can Six Sigma be deployed in Constraints Management for the improvement of manufacturing companies?
3. How can Six Sigma be integrated into manufacturing companies with limited resources?

The study will be tested using through null hypothesis;

H01- Six Sigma cannot be efficiently integrated into the manufacturing process.

H02- Six Sigma cannot be integrated with the Constraints Management to improve the manufacturing process.

H03- Six Sigma cannot be implemented in manufacturing companies with limited resources.

4.0 Literature Review

4.1 Implementation of Six Sigma

According to Al-Mishari and Sulman (2008) businesses could employ three possible approaches in implementing the Six Sigma. These are transformation approach, strategic improvement and problem-solving approach is the third approach. Edgeman and Dugan (2008) cited that the commonly used methodologies in the implementation of Six Sigma are Design, Measure, Analyze, Improve, and Control (DMAIC) and the Design for Six Sigma (DFSS). DMAIC is a problem solving methodology while DFSS is a process defining, designing, and delivering innovative and quality products (Watson & DeYong 2010).

4.2 Six Sigma Tools and Techniques

According to Gitlow and Levine (2005) there are several tools applicable to Six Sigma projects accessible within both public and literature fields. Six Sigma usually provide a customer focused and properly defined methodology that is supported through the establishment of vivid set of inclusive tools meant to improve business processes (Van Iwaarden et al. 2008). According to Van Iwaarden et al. (2008) Six Sigma is an integration of the existing tools and methodologies available before development. The different forms of Six Sigma include the analysis templates, procedures, and models (Yeung 2007). However, there should be improvement tools for the incorporation within the DMAIC process (Gitlow & Levine 2005). However, there are no standard contexts to which the institutional tools can be based (Yeung 2007; Van Iwaarden et al. 2008; Al‐Najjar & Kans 2006). McCarthy and Stauffer (2001) stated that Six Sigma has been in a position of delivering significant results without incorporation of the simulation tools.