OCTOBER 19-20, 2012 - YMCA University of Science & Technology

Proceedings of the National Conference on
Trends and Advances in Mechanical Engineering,
YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012
= ×1,000,000 = × 1,000,000 = 10990
So, DPMO is 10990.
3.4.2 Schimdt and Launsby formula [4]
Sigma = 0.8406 + Sqrt (29.37-2.221×ln(DPMO))
Capability= Sigma/3
So, Sigma = 3.7908.
This clearly shows that defect level has come down and sigma level has improved. It is now 3.79. Finally the success
was achieved in reducing the defect level to such an extent. We could have achieved even more but that required
changes in the whole processes, using high quality machines, automatic machines for clamping and packaging
purpose. All these steps will decrease the manual effort and decrease the time taken thus improving the efficiency of
the process.
3.5 Control phase
The final step in this DMAIC project was to ensure that the proposed improvements should be applied in the
manufacturing process of bricks. Further stress should be paid on other improvements as well particularly in the
method of Firing. There is a need to understand that new methods can further be improved. Also we should
summarize our key learning’s and involve every worker in suggesting improvements. We should also develop a
Monitoring System. Whenever, the inputs were determined to be out of bounds, immediate attention should be given
to correct the situation and bring the process back under control.
4.0 Conclusion
So finally the success was achieved in reducing the defect level and thereby improving the sigma value in. The final
sigma value of 3.79 is achieved. However if industries want to retain or improve this sigma value, necessary control
measures have to be taken and proper checks have to be imposed. Quality culture must be developed amongst
employees and proper training must be given to them. A good decision for project generation not only provides
profits but also increases customer satisfaction. This study aims to investigate the effect of applying six sigma tools
in a Brick Kiln industry trying to decrease the scrap rate. This study has two advantages. First is to choose the best
tools that fit that type of industry. Second is to encourage similar companions to apply the same methodology.
5.0 References
1. Linderman, K., Schroeder, R., Zaheer, S., Choo, A., (2003). “Six Sigma: A goal-theoretic perspective”,
Journal of Operations Management, Vol. 21, No. 2, Mar., pp. 193-203.
2. Pande, P., Neuman, R., Cavanaugh, R., (2000). “The Six Sigma Way: How GE, Motorola, and Other Top
Companies are Honing Their Performance”, McGraw-Hill, New York.
3. Breyfogle, F. W. (2003), “Implementing Six Sigma: Smarter Solutions Using Statistical Methods”, Wiley.
4. Schmidt , S.R., and Launsby, R.G., Understanding Industrial Designed Experiments, 4 th ed., Air Academy
Press, Colorado.
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