Query: Reliability deployment indistributed manufacturing chainsviaclosed-loopSix Sigma methodology

Candidate papers:

abstract: This paper proposes a Six Sigma based framework to deploy high product reliability commitment in distributed subcontractor manufacturing processes. The study aims to expand the Six Sigma tools in applications, where products are designed and developed under the fast time to market requirement. The reliability deployment is driven by two incentives: the customer satisfaction and the reduction of the warranty cost. A closed loop control mechanism is created between the upper and the lower manufacturing streams to identify and remove the early life failures occurred during the initial system installation. A cross functional team is formed to implement Six Sigma tools for resolving critical failures arising in the upper manufacturing stream. The ultimate goal is to achieve high product reliability in the shortest time when the product time to market is essential for gaining the market share. Finally, the proposed control mechanism is demonstrated on the system designs drawn from the semiconductor testing industry.
author_names: Tongdan Jin

Balaji Janamanchi

Qianmei Feng
title: RELIABILITY DEPLOYMENT IN DISTRIBUTED MANUFACTURING CHAINS VIA CLOSED LOOP SIX SIGMA METHODOLOGY
year: 2011

abstract: This paper proposes a Six Sigma based framework to deploy high product reliability commitment in distributed subcontractor manufacturing processes. The study aims to expand the Six Sigma tools in applications, where products are designed and developed under the fast time to market requirement. The reliability deployment is driven by two incentives: the customer satisfaction and the reduction of the warranty cost. A closed loop control mechanism is created between the upper and the lower manufacturing streams to identify and remove the early life failures occurred during the initial system installation. A cross functional team is formed to implement Six Sigma tools for resolving critical failures arising in the upper manufacturing stream. The ultimate goal is to achieve high product reliability in the shortest time when the product time to market is essential for gaining the market share. Finally, the proposed control mechanism is demonstrated on the system designs drawn from the semiconductor testing industry. 2010 Elsevier B.V. All rights reserved.
author_names: Tongdan Jin

Balaji Janamanchi

Qianmei Feng
title: Reliability deployment in distributedmanufacturing chains via closed loop Six Sigma methodology
year: 2015

abstract: The purpose of this paper is to discuss new product development (NPD) based on a traditional stage gate process and to examine how NPD tools, such as Lean design for Six Sigma, can accelerate the achievement of the main goals of NPD: reliable product quality, cost effective implementation, and desired time to market. These new tools must be incorporated into a new approach to NPD based on the Advanced Product and Quality Planning methodology. This research paper is based on the theoretical background presented in peer reviewed scientific research papers during the period 1990 2012. In the second section of this study, the author provides examples of the proposed tools and of advanced techniques to show evidence that validates the hypothesis. This study presented the theoretical background on the NPD process and related functions in today's organizations as it relates to competition. NPD was identified as one of the top priorities of every firm, which is why the NPD process must be optimized and oriented toward customers to ensure the quality and reliability of products while minimizing manufacturing costs. The effect on timing and cost is greatly appreciated by top management, and it is well known throughout the firm when a strong, reliable product is launched that it is flawless. To fully deploy all NPD tools requires basic steps such as the following: marketing and planning, design, process, product process validation and the integration of operations from a concurrent engineering standpoint. This research paper provides step by step guidance in order to apply Lean Sigma tool in NPD process in order to achieve Six Sigma quality level in manufacturing. Promoting the practice of Lean design for Six Sigma and its tool enables firms to increase their competitiveness since they will make more reliable products delivered to its consumers. The approach of this research paper combines proven statistical tools to be applied in an original sequence in order to design robust product to match manufacturing capabilities.
author_names: Jesus Gerardo Cruz Alvarez
title: Lean design for Six Sigma: An integrated approach to achieving product reliability and low cost manufacturing
year: 2015

abstract: Purpose The purpose of this paper is to assess and benchmark Six Sigma strategies in services sector, namely, the telecom field, by establishing tables of fallouts of non conforming services and their associated costs along with a custom data envelopment model for benchmarking the different strategic alternatives. Design/methodology/approach Under normality assumption, process fallout in Six Sigma is around 0.002/3.4 part per million for a centered/shifted process. By introducing Six Sigma to applications in services sector, normality assumption may no longer be valid; hence, fallouts of non normal attributes are computed for different one sided quality levels. The associated costs of strategy deployment, fallout and transaction completion are all considered. Data envelopment analysis model is also established to benchmark the Six Sigma strategic plans. The strategies are detailed down to processes and to quality characteristics which constitute the decision making units. The efficiency of each service unit is computed using both CCR and super efficiency models. Findings The amount of efforts/costs needed to reduce the variation in a service may differ according to the targeted quality level. For the same Six Sigma quality level, services demonstrate different performance/efficiencies and hence different returns. In some scenarios, moderate quality levels could present high efficiencies as compared to services of higher levels. It was also found that the required improvement is less in the case of Log normal as compared to normal distributions at some quality levels. This observation is also noted across the presented distributions of this study (Normal, Log normal, Exponential, Gamma and Weibull) Social implications The deployment of Six Sigma in services is mostly found in time related concepts such as timeliness of billing, lifetimes in reliability engineering, queueing theory, healthcare and telecommunication. Originality/value The paper contributes to the existing research by presenting an assessment model of Six Sigma strategies in services of non normal distributions. Strategies of different quality levels present diverse efficiencies; hence, higher quality levels may not be the best alternatives in terms of the returns on investment. The computed fallout rates of the different distributions can serve as palm lines for further deployment of Six Sigma in services. Besides, the combination of optimization and Six Sigma analysis provides additional benchmarking tool of strategic plans in both manufacturing and services sector.
author_names: Doraid M Dalalah
title: Benchmarking of Six Sigma in telecom services
venue: Benchmarking: An International Journal
year: 2019

abstract: In today's ultra competitive business environment, product life cycles have become shorter. Freeing markets and globalization have increased competition. The reliability, timeliness, accuracy, and perceived value of the products or services have become the keys to company success. The business environment has become turbulent, complex, and even chaotic. To maintain and extend competitive advantages in all dimensions and markets, companies shift increasingly from defining quality as a task that can be run by a quality department, to seeing it as the overall long term umbrella objective of their business. In this era, all manufacturing concerns across the globe are facing new challenges of competitiveness in the emerging markets and struggling hard to improve their financial performances by deploying new quality improvement initiatives. New methods to improve process capabilities and effectiveness are emerging and being applied. This seems to become increasingly important in operational level processes. In their quest to enhance operational level efficiency, market leaders in any segment of business continue to search for the latest quality tools and techniques which can enable them to improve their bottom lines and help them to stay ahead with their global competitors. Undoubtedly, Six Sigma breakthrough methodology coupled with lean practices has had helped world's leading corporations to achieve their aggressive objectives. This paper will address not only basic concepts of Six Sigma but also how this emerging breakthrough methodology has revolutionized the world's leading multinational companies. Subsequently, critical factors to ensure successful implementation of Six Sigma and the key barriers, issues and implementation concerns that lead companies to gain no benefit of its deployment will also be addressed. Further, key imperatives that can ensure successful deployment Pakistan's 9 International Convention on Quality Improvement (ICQI`2005) (c) Pakistan Institute of Quality Control 3 within a SME context will also be part of this endeavor.
author_names: Mr Shafiq Ahmad

Mr Shahid Qureshi
title: HOW TO ACHIEVE AND SUSTAIN OPERATIONAL EXCELLENCE BY IMPLEMENTING SIX SIGMA BREAKTHROUGH METHODOLOGY
year: 2005

abstract: Six Sigma is a known methodology for Process and Quality Improvement. It is also a philosophy, and a set of tools. It is based on the methodology DMAIC (Define, Measure, Analyze, Improve, Control) There are other business process management methodologies related to Six Sigma, such as DFSS (Design For Six Sigma) or Lean Manufacturing (Lean Six Sigma) Six Sigma is notable for using the Scientific Method, and Statistical Techniques. Some of the statistical tools that are used in Six Sigma projects are: Graphic Analysis: Pareto Charts, Histograms, Scatterplots, Box Whisker Charts, Group Charts, Location Charts, Control Charts, Multivari Charts Design of Experiments Regression and Analysis of Variance (ANOVA) Confidence Intervals, Hypothesis Testing Gage R&R Studies Acceptance Sampling, Capability Analysis, Reliability Analysis Commercial statistical software usually includes specific options for Quality Management, for example control charts. There are also a couple of contribution packages in R regarding control charts (qcc, IQCC) but there is no a complete set of tools for Six Sigma. We are currently working in several initiatives aimed at explain and facilitate Six Sigma practitioners to carry on their Six Sigma projects with R, such as a SixSigma package (already at CRAN repositories) with some functions deployed and many others in mind, as well as an on line training course within the EC Lifelong Learning Programme VRTUOSI project, and several publications in preparation.
author_names: Emilio Lopez

R Advantages

Andres Redchuk

Javier M Moguerza
title: Six Sigma Quality Using R Tools and Training
year: 2011

abstract: Despite being an advanced technology, wire bonding in an actual manufacturing setting can greatly affect bond reliability. Many engineering parameters in upstream processes, if not controlled properly, may propagate downstream and limit the bond strength achievable during wire bonding. In this study, the DMAIC approach of Six Sigma methodology was used to improve the wire bonding quality of an opto coupler device developed by an electronic manufacturing firm in Malaysia. Using the five distinctive phases of the DMAIC, the problem was methodologically defined and its contributors identified, which include the improper material handling procedure, the tilted pad, and the un optimised bonding parameters. Corrective actions were deployed and the bond shear force of the device improved using the response surface methodology. The result is an in increase of the average bond shear force of the emitter and detector die from 57.2 g to 77.7 g and from 55.8 g to 66.5 g, respectively.
author_names: Chee Kuang Kok

V S H Yeo

H K Sim
title: Quality improvement for wire bond strength within the semiconductor manufacturing environment
year: 2012

abstract: Six Sigma Implementation at Dow Chemical Company: A Comprehensive Review Introduction The Dow Chemical Company The Six Sigma Program at Dow Preamble and Preparation The Six Sigma Journey Dow's Six Sigma Methodology at Variance The Staircase of Change Leadership Model for Six Sigma Implementation Six Sigma Project Organisational Structure Six Sigma tools, Techniques, Software and Information technology Tools and Techniques used by Dow for Six Sigma projects Six Sigma Software IT and Six Sigma at Dow Where is Dow on its Six Sigma Journey? Selected Case Studies Energy Conservation Studies Polycarbonate Unit Energy Reduction Project System Unit Energy Envelopment Project An Ergonomic Case Study (DMAIC Approach) Lessons and Insights from Dow's Six Sigma program Concluding Remarks Manufacturing Waste Reduction Using Six Sigma Methodology Introduction Project Selection Six Sigma Project: Re winder Performance Define Phase Measure Phase Analyse Phase Improve Phase Sub system CTQ sigma level Gap's Transfer Function Control Phase Temporary Solution Sustained solution Process Capability Control Plan Conclusions Process Improvement at TATA STEEL using the ASPIRE DMAIC approach Tata Steel Company ASPIRE and Six Sigma at TATA STEEL Project Selection Introduction to the project Purpose of Coke Quenching Quenching process ASPIRE DMAIC Approach The Define Phase The Measure Phase The Analyse Phase The Improve Phase The Control Phase Conclusion Improving Product Reliability Using Six Sigma Introduction Six Sigma in the Collaborative Company DMAIC Case Study Define Phase Define the Problem Define the Advocacy team Potential Financial Benefits Project Charter Measure Phase Process Mapping Identify potential causal factors Identify stakeholders' issues Measurement System Analysis Analysis Phase Improve Phase Control Phase Financial confirmation of process capability Stakeholder's issues revisited Agree line inspection frequency Conclusion Reducing the Engine Overheating problem in an Automotive Company using Six Sigma Introduction Case Study Define Phase Measure Phase Analysis Phase Improve Phase Control Phase Key results and financial savings generated from the project Key ingredients of Six Sigma project implementation Conclusion An Application of Six Sigma Methodology to the manufacture of Coal Products Introduction Company background Define Phase Product, Customers and CTQs Project Charter Business Case Statement of the Problem Project Goal Project Scope Team formation Milestones and Communications plan Business process mapping Measure Phase Measurement System Analysis Process Baseline Process Description Analyse Phase Improve Phase Control Phase Economic Benefits obtained Conclusions, comments and lessons learned Six Sigma in Healthcare: A Case Study with Commonwealth Health Corporation (CHC) Introduction to CHC Why Six Sigma in CHC? Six Sigma structure at CHC Six Sigma Methodology Benefits of Six Sigma Critical Success Factors of Six Sigma in Healthcare Clinical Project Example using DMAIC Define Measure Analyse Improve Control Conclusion Six Sigma within Doosan Heavy Industries and Construction Company Introduction Background to Doosan Heavy Industry Doosan's Six Sigma Framework Top level management commitment Stakeholder involvement Training scheme and project team activities Measurement system How to select project themes in Doosan? Doosan's Black Belt Course Case Study Define Measure Analyze Improve Control Doosan's Future Plans in Six Sigma Lean Manufacturing and Six Sigma Differences between Lean and Six Sigma Synergy effect Conclusion Application of Six Sigma in Banking Industry Introduction Why Six Sigma in the Banking Industry? Adoption of Six Sigma in the Banking Industry Introduction to JP Morgan Chase and its use of Six Sigma Introduction to JPMC Investors Services Define Measure Analyze Improve/Implement Control and Project Results Conclusion Some Challenges of Six Sigma in the Banking Industry Future Trends of Six Sigma in Banking Six Sigma Approach to reducing fall hazards among cargo handlers working on top of cargo containers: a case study Introduction and Background Problem Statement Details of cargo handling activities Objectives and overview Define Past statistics on fall accidents in the cargo handling industry in Hong Kong Interview surveys to establish the Working procedures Measure Preliminary interview Measurement tree Questionnaire development Reliability of the questionnaire Measurement I Measurement II Measurement III Analyse Critical factor I Critical factor II Critical factor III Most critical procedure Improve Solution I Solution II Solution III Solution IV Control Conclusion Six Sigma for Government IT: Strategy Tactics for Washington, DC Introduction Motivations Six Sigma and Quality Concepts Information Technology Infrastructure Library Information Technology Infrastructure Library Maturity Assessment and Improvement of Service Level Management Assessment and Improvement of Capacity Management Assessment and Improvement of Financial Management Assessment and Improvement of Availability Management Availability management Define and Measure Phases Availability Management Analyse Phase and Benchmarking Availability Management Conclusions Assessment and Improvement of Service Continuity Define, Measure and Analyse Phases for Service Continuity Continuity Design Phase Continuity Verify Phase Conclusion Increasing Newspaper Accuracy A Case Study Introduction Define Phase Measure Phase Analyse Phase Improve Phase Control Phase Results Success Factors and lessons Learned Deploying Six Sigma Company wide An Application of Six Sigma in Human Resources Alan Harrison Introduction Before Improvements Define Phase People Processes Definition of customer needs and objectives Measure Key Performance Indicators Cost of Poor Quality Analyse Improve Control Achieved Benefits Conclusion
author_names: Jiju Antony

Ricardo Banuelas

Ashok Kumar
title: World class applications of six sigma
year: 2006

abstract: The initial predicted MTBF with four hours MTTR, for a base transceiver system (BTS) is 4.0/5.65 years (MIL217/Bellcore standards) With the first 12 months of commercial operation, with actual field data, the MTBF is calculated to be 8.26 years (Bellcore) which is almost double the initial predicted reliability level. The improved manufacturing techniques with (six sigma quality) advanced system test methods, removal of all defective units in early stages of deployment resulted in tremendous reliability growth which exceeded the initial expected reliability. The downtime per year has decreased from 42 min/yr. to 29 min/yr. and the BTS availability has increased from 99.993% to 99.995% or 5.39 sigma. Further refinement in the reliability is possible by introducing the following steps: (1) establish a minimum qualifying MTBF level for each component of each board; (2) validate the MTBF calculation methodology of vendor of each component; (3) improve MTBF of all weak FRUs by introducing redundancy schemes within each board; (4) introduce individual execution paths for each sector within a BTS; (5) continuous quality improvement techniques to eliminate escaping defects; (6) and establish BTS (HW and SW) stability level with an established release criteria.
author_names: Robert Bothwell

R Donthamsetty

Z Kania

R Wesoloski
title: Reliability evaluation: a field experience from Motorola's cellular base transceiver systems
venue: Proceedings of 1996 Annual Reliability and Maintainability Symposium
year: 1996

abstract: GE remains a leader in the development, deployment and advancement of Six Sigma techniques to minimize manufacturing cycle time, reduce process variability, and optimize product quality. Recently GE Medical Systems Information Technologies collaborated with Plexus to develop a completely revamped version of its Transport Pro Display. The Transport Pro Display enables continuous display of vital signs in transit and captures an unbroken monitoring history both critical requirements for vital signs monitoring. The need to be highly reliable during transport of the patient among varied environments within the hospital (operating room, emergency department, ICU, procedure room, etc. further drove requirements for the design. By applying Design For Six Sigma methodologies the joint team set reliability objectives early in the design process aimed at realizing a robust product with high manufacturing yields, minimal process variation, and high availability in the field. Through a combination of clearly defined product and lower level design requirements, rigorous design analysis, milestone driven, in depth design reviews, and relentless testing, the joint team successfully met its six sigma objectives enabling GEMS IT to launch a highly accepted product that continues to exceed market forecasts. This paper details the tools and techniques used to implement a successful Design For High Reliability medical device development project. It additionally focuses on the unique requirements when collaborating with an outside supplier who must adapt to the OEM's internal processes, culture, and development environment to serve as an effective extension of the OEM's internal team. Manufacturing process yield and field failure data are presented to quantitatively demonstrate the effectiveness of the approach.
author_names: Chris M Rozewski

Michael Tendick
title: FOR HIGH RELIABILITY MEETING THE GOALS OF HIGH YIELD AND REDUCED FIELD FAILURES DURING THE MEDICAL PRODUCT DEVELOPMENT PROCESS
year: 2004