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USE of SHAININ TOOLS for SIMPLIFYING SIX SIGMA IMPLEMENTATION in QMS/ISO CERTIFIED ENVIRONMENT– an INDIAN SME CASE STUDY Anand K

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USE of SHAININ TOOLS for SIMPLIFYING SIX SIGMA IMPLEMENTATION in QMS/ISO CERTIFIED ENVIRONMENT– an INDIAN SME CASE STUDY Anand K Journal of Engineering Research and Studies E-ISSN 0976-7916 Research Article USE OF SHAININ TOOLS FOR SIMPLIFYING SIX SIGMA IMPLEMENTATION IN QMS/ISO CERTIFIED ENVIRONMENT– AN INDIAN SME CASE STUDY Anand K. Bewoor*, Maruti S. Pawar Address for Correspondence *1Mechanical Engineering Dept.,Vishwakarama Institute of Information Tech.,Kondhwa (Bk), Pune 411048, Maharashtra, India 2Professor and Vice-Principal, B. M. I. T., Solapur University, Solapur Maharashtra, India. E-mail: [email protected], [email protected] ABSTRACT Six sigma for small- and medium-sized enterprises (SMEs) is an emerging topic among many academics and Six Sigma practitioners over the last two to three years. Very few studies have been reported about the successful applications of Six Sigma in SMEs. Main objective of this paper is to examine the extent of usefulness of a simpler but not very frequently used methodology known as the Shainin methodology for simplifying the implementing Six Sigma. To confirm whether Six Sigma implementation is simplified, this paper highlights the comparison of three DOE approaches viz. Classical, Taguchi and Shainin methodology. A case study based research work done in ISO certified Indian SME, concludes that, Six Sigma implementation process can be simplified by using Shainin tools and proper use company’s ISO/QMS. KEYWORDS Six Sigma, Shainin Tools, QMS, Indian SMEs. 1. INTRODUCTION and new product and service development. In recent past, academicians, practitioners Six Sigma relies on statistical methods and and organizational researchers have the scientific method to make dramatic recognized that the Quality Management reductions in customer defined defect System (QMS) process and the Six-Sigma rates’’ (Linderman et al., 2003). Since its process are disciplines that have a initiation at Motorola in the 1980s, many powerful potential to affect an companies including GE, Honeywell, organization’s ability to compete within Sony, Caterpillar, Johnson Controls etc. an increasingly global and dynamic have adopted Six Sigma and obtained marketplace (Falshaw et al., 2006). QMS substantial benefits (Pande et al., 2000). certification (such as ISO 9000, TS Spectacular development of an 16949) demonstrates the capability of an organizational performance due to Six industry to control the processes that Sigma implementation many companies determine the acceptability of the product are reported in the published literature. or service being produced & sold. These, Antony and Banuelas (2002) presented the traditional QMS are having some key ingredients for the effective limitations like methodological assistance introduction and implementation of Six- etc. (Bewoor and Pawar, 2008). But new Sigma in manufacturing and services QM methods continue to grow (Xingxing organizations as: Management commit- Zu et. al., 2008) for example, Six Sigma, ment and involvement, Understanding of which is ‘‘an organized and systematic Six Sigma methodology, tools, and method for strategic process improvement techniques, Linking Six Sigma to business JERS/Vol.I/ Issue II/Oct.-Dec.,2010/177-194 Journal of Engineering Research and Studies E-ISSN 0976-7916 strategy, to customers, to suppliers, project resulted in to more benefit on operational selection, reviews and tracking, level (Bewoor and Pawar, 2009). This organizational infrastructure, Cultural case based study helped us to understand change, Project management skills, that if we use simple to use tools, we can Training. All these ingredients make the simplify Six Sigma implementation Six Sigma process as a complex process process. The observations and experiences and very little efforts has been made for in the above case study leads to question simplifying the process of Six Sigma about how to simplify the implementation implementation process by making use of of Six Sigma with or without QMS/ISO existing QMS and by selecting proper systems. The main complex part of the implementation tools. Some of the implementation of Six Sigma is the criticisms of the Six Sigma methodology selection and use of tools for solving perhaps stems from the fact that it is problems. It is observed that, the efforts to sometimes too statistical and beyond simplify the implementation of Six Sigma comprehension of the people involved in are needed in the area of use of tools. One implementing it in practice. Eckes (2001) of such efforts/studies is presented below. is of the opinion that Six Sigma initiatives 2.PRESENT METHODOLOGIES FOR can fail if the organization believes that SIX SIGMA IMPLEMENTATIONS better quality is possible only through the Pyzdek (2003) has classified Six Sigma use of sophisticated statistical tools. The tools into three categories (refer table 1), objective of this paper is to examine as to (i) Basic Six Sigma methods (are further how to simplify and demystify the use of categorized as problem solving tools, 7M Shainin tools for Six Sigma tools, and knowledge discovery tools). (ii) implementation tools. At present, the Intermediate Six Sigma methods include a impacts of QMS and Six Sigma processes host of enumerative and analytical on an organization’s ability to compete statistical tools like Distributions, have been examined independently. Very Statistical inference, Basic control charts, little emphasis has been given by the exponentially weighted moving average researchers to conceptually examine the (EWMA) charts etc.). (iii) Advanced Six potential impact of the synergistic effects Sigma methods are Design of experiments that might be gained from merging various (DOE) Regression and correlation analysis quality management principles and those Process capability analysis etc. At the of Six-Sigma process. After doing clause- heart of the Six Sigma approach is the wise analysis Bewoor and Pawar, (2008) application of DOE techniques. These had proposed the ‘Six Sigma+QMS/ISO’ techniques help to identify key factors and an integrated concept and successfully to subsequently adjust these factors in validated its applicability with the help of order to achieve sustainable performance case study based research. This has improvements. JERS/Vol.I/ Issue II/Oct.-Dec.,2010/177-194 Journal of Engineering Research and Studies E-ISSN 0976-7916 Table 1 : Basic Six Sigma Tools Problem Solving Tools 7M Tools Knowledge Discovery Tools Process mapping Affinity diagrams Run charts Flow charts Process decision program charts Descriptive statistics Check sheets Matrix diagrams & Histograms Tree diagrams Pareto analysis Interrelationship diagraphs Exploratory data analysis Cause-and-effect Prioritization matrices diagrams Scatter plots Activity network diagrams (Source: Pyzdek, 2003) While the basic and intermediate methods identification of the root cause of the are relatively easier to understand and use, problem out of the potential Xs. the advanced methods are perceived to be Experimental design is one of the tried difficult to comprehend and interpret. and tested statistical techniques long used Design of Experiments (DOE) is one such by industrial engineers to identify the key tool. The complexity of these DOE variables affecting output. Through techniques that are often cited by designed experiments, changes are companies as to the reason why they are deliberately introduced into the process to unable to employ Six Sigma. A short better understand which of the Xs are overview of the DOE techniques is affecting the output variable. presented next. There are two well-known approaches 2.1 Experimental Design using to experimental design. The first approach Classical and Taguchi Approach is the classical design of experiments A classical DOE approach would have credited to Sir Ronald Fisher who initially meant application of factorial designs experimented in the field of agriculture. requiring much more time and effort, and However, this method is now widely used above all, it would have required changes in many fields. The second approach is the in machine settings. Classical DOE Taguchi approach pioneered by Dr requires large data collection to conduct Genichi Taguchi of Japan who adopted the the analysis. Six Sigma process classical approach to reintroduce the improvements consist of analyzing concept of orthogonal arrays used for relationships between an output variable designing experiments in different fields (Y) explained wholly or partly by process (Rao, et al.). The commonly used classical variables (Xs) that affect the output. A key Design of Experiment (DOE) tools are the step in Six Sigma projects is the family of factorial experiments consisting JERS/Vol.I/ Issue II/Oct.-Dec.,2010/177-194 Journal of Engineering Research and Studies E-ISSN 0976-7916 of full factorial designs and fractional problems into three X’s, viz., the Red X, factorial designs. A full factorial allows us the Pink X- the second most important to test all possible combinations of factors cause(s), and the Pale Pink X – the third affecting output in order to identify which most important cause(s). According to ones are more dominant. A fractional him, these three Xs together account for factorial tests just a fraction of the over 80 per cent of the variation that is possible combinations. Though a very allowed within the specification limit and popular tool, many engineers and quality when captured, reduced, and controlled, practitioners find design of experiments these can eliminate this variation. Shainin difficult primarily because of the developed techniques (Shainin and complexity of having to create the Shainin,
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