Bir süpermarkette Altı Sigma yöntemiyle ürün iadelerinin azaltılması
Year 2024,
Volume: 14 Issue: 1, 85 - 97, 15.03.2024
Ayşe Çelik
,
İzzettin Hakan Karaçizmeli
Abstract
Son dönemlerde birçok sektörde yaşanan rekabet artışı, işletmelerin süreç iyileştirme arayışlarının da artmasına neden olmuştur. Rakiplerinden önde olmak isteyen firmalar, üretim sektöründe genellikle operasyonlarda iyileştirme yaparak maliyetleri azaltma yönünde arayışlara girerken, hizmet sektöründe ise daha çok müşteri memnuniyeti üzerine çalışmalar yapmaktadırlar. Müşteri memnuniyetinin artması hem müşterileri kalıcı hale getirmek hem de müşteri sayısını artırmak açısından oldukça önemlidir. Altı Sigma yöntemi daha çok, büyük kurumsal şirketlerde tercih edilmektedir. Ancak bu çalışmada kaynakları çok geniş olmayan işletmeler için basit bir çerçeve önerilmiştir. Bu amaçla Şanlıurfa’daki büyük çaplı bir süpermarkette kurumsal müşterilerden gelen ürün iadelerini azaltmak için Altı Sigma yöntemi uygulanmıştır. Altı Sigma yönteminin adımları kullanılarak potansiyel hata nedenleri belirlenmiş, toplanan verilerin analizleri yapılmıştır. İade nedenlerini kapsayan, toplanan verilerin analiz edilmesiyle ön plana çıkan faktörler beyin fırtınası ile belirlenen potansiyel hata nedenleriyle eşleştirildi. Kurumsal müşterilerden gelen ürün iadelerini derinden etkileyen iki kök neden, sipariş alan personelin yetersiz eğitimi ve sipariş formunun olmamasıdır. Bu iki kök neden toplam ürün iadelerinin %61’ini oluşturmuştur. Uygulama sonunda ürün iadelerini azaltmak için bazı iyileştirme aksiyonları alınmış ve sürdürülebilirliği sağlamak için izleme sistemi kurulmuştur.
References
- Aişeoğlu, S., & Karaçizmeli, İ.H. (2022). Reducing inventory levels in a supermarket through the Six Sigma method. Bitlis Eren University Journal of Science, 11(3), 828-835. https://doi.org/10.17798/bitlisfen.1122251
- Akarslan, B. (2003). Six Sigma method and an implementation of the method [MSc Thesis, Istanbul Technical University Graduate School Industrial Engineering Department].
- Arya, A.K., & Jain, S.K. (2014). Impacts of Kaizen in a small-scale industry of India: A case study. International Journal of Lean Six Sigma, 5(1), 22-44. https://doi.org/10.1108/IJLSS-03-2013-0019
- Avunduk, H. (2019). Yalın Altı Sigma: Bir pet şişirme makinesinde süreç iyileştirme uygulaması. Electronic Journal of Social Sciences, 18(70), 633-653. https://doi.org/10.17755/esosder.428802
- Cengiz, Ö., & Senger, Ö. (2018). Hizmet sektöründe Altı Sigma kalite felsefesinin uygulanması: Bir turizm işletmesi örneği. Alphanumeric Journal, 6(1), 151–176. https://doi.org/10.17093/alphanumeric.396671
- Cherry, J., & Seshadri, S. (2000). Six Sigma: Using statistics to reduce process variability and costs in radiology. Radiology Management, 22, 42-49.
- Erbiyik, H., & Saru, M. (2015). Six Sigma implementations in supply chain: An application for an automotive subsidiary industry in Bursa in Turkey. Procedia-Social and Behavioral Sciences, 195, 2556-2565. https://doi.org/10.1016/j.sbspro.2015.06.447
- Falcón, R. G., Alonso, D. V., Fernández, L. M. G., & Peres-Lombard, L. (2012). Improving energy efficiency in a naphtha reforming plant using Six Sigma methodology. Fuel Processing Technology, 103, 110-116. https://doi.org/10.1016/j.fuproc.2011.07.010
- Franchetti, M., & Barnala, P. (2013). Lean Six Sigma at a material recovery facility: A case study, International Journal of Lean Six Sigma, 4(3), 251-264. https://doi.org/10.1108/IJLSS-05-2013-0026
- Gerger, A., & Demir, B. (2010). A sample for increasing of proportion of service customer relationship with using Lean Six Sigma in automotive services. Electronic Journal of Vehicle Technologies, 2(1), 33-47.
- Hakimi, S., Zahraee, S.M., & Rohani, J.M. (2018). Application of Six Sigma DMAIC methodology in plain yogurt production process. International Journal of Lean Six Sigma, 9(4), 562-578. https://doi.org/10.1108/IJLSS-11-2016-0069
- Hussein, N.A., Abdelmaguid, T.F., Tawfik, B.S., & Ahmed, N.G.S. (2017). Mitigating overcrowding in emergency departments using Six Sigma and simulation: A case study in Egypt. Operations Research for Health Care, 15, 1-12. https://doi.org/10.1016/j.orhc.2017.06.003
- Indrawati, S., & Ridwansyah, M. (2015). Manufacturing continuous improvement using Lean Six Sigma: An iron ores industry case application. Procedia Manufacturing, 4, 528-534. https://doi.org/10.1016/j.promfg.2015.11.072
- Maleyeff J. (2007). Improving service delivery in government with Lean Six Sigma. Strategy and Transformation Series, IBM Center for The Business of Government, Washington, DC.
- Mitreva, E., & Kirovski, F. (2021). Application of the methodology of Six Sigma in public health institution. SAR Journal, 4(3), 107-113.
- Nedeliaková, E., Štefancová, V., & Kudláč, S. (2017). Six Sigma and dynamic models application as an important quality management tool in railway companies. Procedia Engineering, 187, 242-248. https://doi.org/10.1016/j.proeng.2017.04.371
- Pathiratne, S.U., Khatibi, A., & Johar, M.G.M. (2018). CSFs for Six Sigma in service and manufacturing companies: An insight on literatüre. International Journal of Lean Six Sigma, 9(4), 543-561. https://doi.org/10.1108/IJLSS-08-2017-0092
- Prakash, S., Kumar, S., Soni, G., Mahto, R.V., & Pandey, N. (2022). A decade of the International Journal of Lean Six Sigma: Bibliometric overview. International Journal of Lean Six Sigma, 13(2), 295-341. https://doi.org/10.1108/IJLSS-12-2020-0219
- Pugna, A.P., Negrea, R., & Miclea, Ş. (2016). Using Six Sigma methodology to improve the assembly process in an automotive company. Procedia-Social and Behavioral Sciences, 221, 308-316. https://doi.org/10.1016/j.sbspro.2016.05.120
- Ratnaningtyas, D.D., & Surendro, K. (2013). Information quality improvement model on hospital information system using Six Sigma. Procedia Technology, 9, 1166-1172. https://doi.org/10.1016/j.protcy.2013.12.130
- Ray, S., & Das, P. (2010). Six Sigma project selection methodology. International Journal of Lean Six Sigma, 1(4), 293-309. https://doi.org/10.1108/20401461011096078
- Riggle, J.D., Paulman, R.A., Lazure, J.L., Hallbeck, M.S., & Gannon, D.E. (2018). Structured redesign of a hospital-based code response team using Six Sigma tools and human factors principles to facilitate teamwork. Journal of Interprofessional Education & Practice, 12(1), 57-64. https://doi.org/10.1016/j.xjep.2018.06.001
- Sahoo, A.K., Tiwari, M.K., & Mileham, A.R. (2008). Six Sigma based approach to optimize radial forging operation variables. Journal of Materials Processing Technology, 202(1–3), 125-136. https://doi.org/10.1016/j.jmatprotec.2007.08.085
- Schmidt, H.G. (2019). Use of Lean Six Sigma methods to eliminate fume hood disorder. Journal of Chemical Health and Safety, 26(6), 12-16. https://doi.org/10.1016/j.jchas.2019.03.006
- Smetkowska, M., & Mrugalska, B. (2018). Using Six Sigma DMAIC to improve the quality of the production process: A case study. Procedia-Social and Behavioral Sciences, 238, 590-596. https://doi.org/10.1016/j.sbspro.2018.04.039
- Snee, R.D. (2006). Increasing newspaper accuracy using Six Sigma methodology. In Antony J., Banuelas R., & Kumar A. (Ed.s), World Class Applications of Six Sigma, (pp. 211-223). Elsevier, Amsterdam.
- Sommer, A.C., & Blumenthal, E.Z. (2019). Implementation of Lean and Six Sigma principles in ophthalmology for improving quality of care and patient flow. Survey of Ophthalmology, 64(5), 720-728. https://doi.org/10.1016/j.survophthal.2019.03.007
- Sreedharan, V.R., & Raju, R. (2016). A systematic literature review of Lean Six Sigma in different industries. International Journal of Lean Six Sigma, 7(4), 430-466. https://doi.org/10.1108/IJLSS-12-2015-0050
- Srinivasan, K., Muthu, S., Devadasan, S.R., & Sugumaran, C. (2014). Enhancing effectiveness of shell and tube heat exchanger through Six Sigma DMAIC phases. Procedia Engineering, 97, 2064-2071. https://doi.org/10.1016/j.proeng.2014.12.449
- Srinivasan, K., Muthu, S., Prasad, N.K., & Satheesh, G. (2014). Reduction of paint line defects in shock absorber through Six Sigma DMAIC phases. Procedia Engineering, 97, 1755-1764. https://doi.org/10.1016/j.proeng.2014.12.327
- Tagge, E.P., Thirumoorthi, A.S., Lenart, J., Garberoglio, C., & Mitchell, K.W. (2017). Improving operating room efficiency in academic children's hospital using Lean Six Sigma methodology. Journal of Pediatric Surgery, 52(6), 1040-1044. https://doi.org/10.1016/j.jpedsurg.2017.03.035
- Tezsürücü, D., & Tunail, İ. (2010). Altı Sigma metodolojisi ve otomotiv sektöründe bir örnek olay incelemesi. Manisa Celal Bayar Üniversitesi Sosyal Bilimler Dergisi, 8(1), 129-146.
- Tjahjono, B., Ball, P., Vitanov, V.I., Scorzafave, C., Nogueira, J., Calleja, J., Minguet, M., Narasimha, L., Rivas, A., Srivastava, A., Srivastava, S., & Yadav, A. (2010). Six Sigma: A literature review. International Journal of Lean Six Sigma, 1(3), 216-233. https://doi.org/10.1108/20401461011075017
- Vivekananthamoorthy, N., & Shanmuganathan, S. (2011). Lean Six Sigma. In Coskun, A., İnal, T.C. & Serteser, M. (Ed.s), Six Sigma Projects and Personal Experiences, (pp. 1-22). IntechOpen, London.
- Wyper B., & Harrison, A. (2000). Deployment of Six Sigma methodology in human resource function: A case study. Total Quality Management, 11(4-6), 720-727. https://doi.org/10.1080/09544120050008129
- Yüksel, H. (2012). Six Sigma applications in service firms: A literature review. The Journal of Selcuk University Social Sciences Institute, 27, 327-338.
Reducing product returns through the Six Sigma method in a supermarket
Year 2024,
Volume: 14 Issue: 1, 85 - 97, 15.03.2024
Ayşe Çelik
,
İzzettin Hakan Karaçizmeli
Abstract
The intense competition in many sectors in recent years has led businesses to seek process improvement methods. While businesses that desire to be ahead of their competitors often try to reduce costs by improving operations in production, they focus on customer satisfaction in the service sector. Increasing customer satisfaction is quite significant because it not only ensures customer loyalty but also increases the number of customers. The Six Sigma method is mostly preferred by large corporate companies. However, in this study, a simple framework is proposed for businesses whose resources are not very large. To this end, the Six Sigma method was implemented to reduce product returns from corporate customers in a large-scale supermarket in Şanlıurfa. The potential causes of defects were determined by following the steps involved in the Six Sigma method, and the collected data were analyzed. By analyzing the collected data covering the reasons for product returns, the factors that came to the fore were matched with the potential causes determined by brainstorming. The two root causes deeply that affected the product returns from corporate customers were the insufficient training of the staff taking the orders and the lack of an order form. These two root causes accounted for 61% of the total product returns. Then some improvement actions were taken to reduce the product returns, and a monitoring system was established to ensure sustainability.
References
- Aişeoğlu, S., & Karaçizmeli, İ.H. (2022). Reducing inventory levels in a supermarket through the Six Sigma method. Bitlis Eren University Journal of Science, 11(3), 828-835. https://doi.org/10.17798/bitlisfen.1122251
- Akarslan, B. (2003). Six Sigma method and an implementation of the method [MSc Thesis, Istanbul Technical University Graduate School Industrial Engineering Department].
- Arya, A.K., & Jain, S.K. (2014). Impacts of Kaizen in a small-scale industry of India: A case study. International Journal of Lean Six Sigma, 5(1), 22-44. https://doi.org/10.1108/IJLSS-03-2013-0019
- Avunduk, H. (2019). Yalın Altı Sigma: Bir pet şişirme makinesinde süreç iyileştirme uygulaması. Electronic Journal of Social Sciences, 18(70), 633-653. https://doi.org/10.17755/esosder.428802
- Cengiz, Ö., & Senger, Ö. (2018). Hizmet sektöründe Altı Sigma kalite felsefesinin uygulanması: Bir turizm işletmesi örneği. Alphanumeric Journal, 6(1), 151–176. https://doi.org/10.17093/alphanumeric.396671
- Cherry, J., & Seshadri, S. (2000). Six Sigma: Using statistics to reduce process variability and costs in radiology. Radiology Management, 22, 42-49.
- Erbiyik, H., & Saru, M. (2015). Six Sigma implementations in supply chain: An application for an automotive subsidiary industry in Bursa in Turkey. Procedia-Social and Behavioral Sciences, 195, 2556-2565. https://doi.org/10.1016/j.sbspro.2015.06.447
- Falcón, R. G., Alonso, D. V., Fernández, L. M. G., & Peres-Lombard, L. (2012). Improving energy efficiency in a naphtha reforming plant using Six Sigma methodology. Fuel Processing Technology, 103, 110-116. https://doi.org/10.1016/j.fuproc.2011.07.010
- Franchetti, M., & Barnala, P. (2013). Lean Six Sigma at a material recovery facility: A case study, International Journal of Lean Six Sigma, 4(3), 251-264. https://doi.org/10.1108/IJLSS-05-2013-0026
- Gerger, A., & Demir, B. (2010). A sample for increasing of proportion of service customer relationship with using Lean Six Sigma in automotive services. Electronic Journal of Vehicle Technologies, 2(1), 33-47.
- Hakimi, S., Zahraee, S.M., & Rohani, J.M. (2018). Application of Six Sigma DMAIC methodology in plain yogurt production process. International Journal of Lean Six Sigma, 9(4), 562-578. https://doi.org/10.1108/IJLSS-11-2016-0069
- Hussein, N.A., Abdelmaguid, T.F., Tawfik, B.S., & Ahmed, N.G.S. (2017). Mitigating overcrowding in emergency departments using Six Sigma and simulation: A case study in Egypt. Operations Research for Health Care, 15, 1-12. https://doi.org/10.1016/j.orhc.2017.06.003
- Indrawati, S., & Ridwansyah, M. (2015). Manufacturing continuous improvement using Lean Six Sigma: An iron ores industry case application. Procedia Manufacturing, 4, 528-534. https://doi.org/10.1016/j.promfg.2015.11.072
- Maleyeff J. (2007). Improving service delivery in government with Lean Six Sigma. Strategy and Transformation Series, IBM Center for The Business of Government, Washington, DC.
- Mitreva, E., & Kirovski, F. (2021). Application of the methodology of Six Sigma in public health institution. SAR Journal, 4(3), 107-113.
- Nedeliaková, E., Štefancová, V., & Kudláč, S. (2017). Six Sigma and dynamic models application as an important quality management tool in railway companies. Procedia Engineering, 187, 242-248. https://doi.org/10.1016/j.proeng.2017.04.371
- Pathiratne, S.U., Khatibi, A., & Johar, M.G.M. (2018). CSFs for Six Sigma in service and manufacturing companies: An insight on literatüre. International Journal of Lean Six Sigma, 9(4), 543-561. https://doi.org/10.1108/IJLSS-08-2017-0092
- Prakash, S., Kumar, S., Soni, G., Mahto, R.V., & Pandey, N. (2022). A decade of the International Journal of Lean Six Sigma: Bibliometric overview. International Journal of Lean Six Sigma, 13(2), 295-341. https://doi.org/10.1108/IJLSS-12-2020-0219
- Pugna, A.P., Negrea, R., & Miclea, Ş. (2016). Using Six Sigma methodology to improve the assembly process in an automotive company. Procedia-Social and Behavioral Sciences, 221, 308-316. https://doi.org/10.1016/j.sbspro.2016.05.120
- Ratnaningtyas, D.D., & Surendro, K. (2013). Information quality improvement model on hospital information system using Six Sigma. Procedia Technology, 9, 1166-1172. https://doi.org/10.1016/j.protcy.2013.12.130
- Ray, S., & Das, P. (2010). Six Sigma project selection methodology. International Journal of Lean Six Sigma, 1(4), 293-309. https://doi.org/10.1108/20401461011096078
- Riggle, J.D., Paulman, R.A., Lazure, J.L., Hallbeck, M.S., & Gannon, D.E. (2018). Structured redesign of a hospital-based code response team using Six Sigma tools and human factors principles to facilitate teamwork. Journal of Interprofessional Education & Practice, 12(1), 57-64. https://doi.org/10.1016/j.xjep.2018.06.001
- Sahoo, A.K., Tiwari, M.K., & Mileham, A.R. (2008). Six Sigma based approach to optimize radial forging operation variables. Journal of Materials Processing Technology, 202(1–3), 125-136. https://doi.org/10.1016/j.jmatprotec.2007.08.085
- Schmidt, H.G. (2019). Use of Lean Six Sigma methods to eliminate fume hood disorder. Journal of Chemical Health and Safety, 26(6), 12-16. https://doi.org/10.1016/j.jchas.2019.03.006
- Smetkowska, M., & Mrugalska, B. (2018). Using Six Sigma DMAIC to improve the quality of the production process: A case study. Procedia-Social and Behavioral Sciences, 238, 590-596. https://doi.org/10.1016/j.sbspro.2018.04.039
- Snee, R.D. (2006). Increasing newspaper accuracy using Six Sigma methodology. In Antony J., Banuelas R., & Kumar A. (Ed.s), World Class Applications of Six Sigma, (pp. 211-223). Elsevier, Amsterdam.
- Sommer, A.C., & Blumenthal, E.Z. (2019). Implementation of Lean and Six Sigma principles in ophthalmology for improving quality of care and patient flow. Survey of Ophthalmology, 64(5), 720-728. https://doi.org/10.1016/j.survophthal.2019.03.007
- Sreedharan, V.R., & Raju, R. (2016). A systematic literature review of Lean Six Sigma in different industries. International Journal of Lean Six Sigma, 7(4), 430-466. https://doi.org/10.1108/IJLSS-12-2015-0050
- Srinivasan, K., Muthu, S., Devadasan, S.R., & Sugumaran, C. (2014). Enhancing effectiveness of shell and tube heat exchanger through Six Sigma DMAIC phases. Procedia Engineering, 97, 2064-2071. https://doi.org/10.1016/j.proeng.2014.12.449
- Srinivasan, K., Muthu, S., Prasad, N.K., & Satheesh, G. (2014). Reduction of paint line defects in shock absorber through Six Sigma DMAIC phases. Procedia Engineering, 97, 1755-1764. https://doi.org/10.1016/j.proeng.2014.12.327
- Tagge, E.P., Thirumoorthi, A.S., Lenart, J., Garberoglio, C., & Mitchell, K.W. (2017). Improving operating room efficiency in academic children's hospital using Lean Six Sigma methodology. Journal of Pediatric Surgery, 52(6), 1040-1044. https://doi.org/10.1016/j.jpedsurg.2017.03.035
- Tezsürücü, D., & Tunail, İ. (2010). Altı Sigma metodolojisi ve otomotiv sektöründe bir örnek olay incelemesi. Manisa Celal Bayar Üniversitesi Sosyal Bilimler Dergisi, 8(1), 129-146.
- Tjahjono, B., Ball, P., Vitanov, V.I., Scorzafave, C., Nogueira, J., Calleja, J., Minguet, M., Narasimha, L., Rivas, A., Srivastava, A., Srivastava, S., & Yadav, A. (2010). Six Sigma: A literature review. International Journal of Lean Six Sigma, 1(3), 216-233. https://doi.org/10.1108/20401461011075017
- Vivekananthamoorthy, N., & Shanmuganathan, S. (2011). Lean Six Sigma. In Coskun, A., İnal, T.C. & Serteser, M. (Ed.s), Six Sigma Projects and Personal Experiences, (pp. 1-22). IntechOpen, London.
- Wyper B., & Harrison, A. (2000). Deployment of Six Sigma methodology in human resource function: A case study. Total Quality Management, 11(4-6), 720-727. https://doi.org/10.1080/09544120050008129
- Yüksel, H. (2012). Six Sigma applications in service firms: A literature review. The Journal of Selcuk University Social Sciences Institute, 27, 327-338.