DMAIC Cycle for the New Product Launch Process: FMEA and DOE Applications for Built-In Oven

Year 2024, Volume: 58 Issue: 1, 29 - 44, 31.01.2024

Ezgi Aktar Demirtaş , Gamze Yetimler Kostur , Mehmet Erol Kara

https://doi.org/10.51551/verimlilik.1319240

Abstract

Objective: Six Sigma-SS and the DMAIC-Define, Measure, Analyze, Improve, Control cycle are employed to enhance the success of the launch of a new built-in oven with a digital panel.
Method: Following the define and measure phases, to identify and eliminate potential failures, Failure Mode and Effect Analysis-FMEA is conducted and control plans were composed during the analyse phase. In the improvement phase, the Risk Priority Numbers-RPNs obtained through FMEA and recommendations were listed. Using Design of Experiments-DOE, the lifespan of bulbs in ovens was maintained at the target value while reducing procurement costs. In the control phase, the results of validation experiments and the gains were reported.
Findings: After reporting the RPNs related to high-risk failure modes and providing improvement recommendations, DOE and Analysis of Variance were employed to determine which type of oven and brand of bulb could be used. If implemented, the expected annual savings are approximately 20,000 Euros.
Originality: This article focuses on an integrated approach for a product that is set for a new launch. It aims to improve design and production processes using the SS while also targeting cost reduction in procurement processes. To the best of our knowledge, no similar study has been encountered in the literature.

Keywords

Six Sigma, Built-in Oven, Design of Experiment, Failure Mode and Effect Analysis

Yeni Bir Ankastre Fırını Devreye Alma Sürecinde TÖAİK Döngüsü: HTEA Ve DT Uygulamaları

Abstract

Amaç: Altı Sigma Metodolojisi ve TÖAİK-Tanımla, Ölç, Analiz Et, İyileştir, Kontrol Et döngüsü ile ilk kez piyasaya sunulacak olan dijital panelli ankastre bir fırın lansmanının başarısını artırmak hedeflenmiştir.
Yöntem: Tanımlama ve ölçme aşamasını takip eden analiz aşamasında Hata Türü ve Etki Analizi-HTEA ile muhtemel hata kaynakları belirlenip elimine edilmeye çalışılmış, kontrol planları oluşturulmuştur. İyileştirme aşamasında, HTEA ile elde edilen Risk Öncelik Sayıları (RÖS) ve iyileştirme önerileri listelenmiştir. Deney Tasarımı (DT) ile ankastre fırınlarda kullanılan ampül ömrünü hedef değerde tutarak satın alma maliyetlerini düşürmek amaçlanmıştır. Kontrol aşamasında doğrulama deneylerinin sonuçları ile elde edilen kazançlar raporlanmıştır.
Bulgular: Yüksek riskli hata türlerine ilişkin RÖS ve iyileştirme önerileri raporlandıktan sonra DT ve Varyans Analizi ile hangi fırın tipinde hangi marka ampülün kullanılabileceği tespit edilmiştir. Uygulamaya geçilmesi halinde beklenen yıllık kazanç yaklaşık 20.000 Euro civarındadır.
Özgünlük: Bu makale; henüz seri üretime geçmemiş ve yeni devreye alınacak olan bir ürün için, Altı Sigma yaklaşımı ile tasarım ve üretim süreçlerini iyileştirirken, satın alma süreçlerinde de maliyeti azaltmayı hedefleyen bütünleşik bir yaklaşıma odaklanmaktadır. Bilindiği kadarıyla literatürde benzer çalışmaya rastlanmamıştır.

Keywords

Altı Sigma, Ankastre Fırın, Deney Tasarımı, Hata Türü ve Etki Analizi

References

• Ahmad, N., Hossen, J. and Ali, S.M. (2018). “Improvement of Overall Equipment Efficiency of Ring Frame Through Total Productive Maintenance: A Textile Case”, The International Journal of Advanced Manufacturing Technology, 94, 239-256.
• Ajmera, R., Umarani, P. and Valase, K.G. (2017). “Lean Six Sigma Implementation in Textile Industry”, International Research Journal of Engineering and Technology (IRJET), 4(4), 1670-1676.
• Antony, J. (2002). "Training for Design of Experiments Using a Catapult”, Quality and Reliability Engineering International, 18(1), 29-35.
• Antony, J. and Banuelas, R. (2002). “Key Ingredients for the Effective Implementation of Six Sigma Program”, Measuring Business Excellence, 6(4), 20-27.
• Antony, J., Kumar, M. and Labib, A. (2008). “Gearing Six Sigma into UK Manufacturing SMEs: Results from a Pilot Study”, Journal of the Operational Research Society, 59(4), 482-493.
• Atmaca, E. and Girenes, S. S. (2013). “Lean Six Sigma Methodology and Application”, Quality & Quantity, 47, 2107-2127.
• Banuelas, R., Antony, J. and Brace, M. (2005). “An Application of Six Sigma to Reduce Waste”, Quality and Reliability Engineering International, 21(6), 553-570.
• Cheng, C.S. and Kuan, C.M. (2012). “Research on Product Reliability Improvement by Using DMAIC Process: A Case Study of Cold Cathode Fluorescent Lamp”, Asian Journal on Quality, 13(1), 67-76.
• Costa, J.P., Lopes, I.D.S. and Brito, J.P. (2019). “Six Sigma Application for Quality Improvement of the Pin Insertion Process”, Procedia Manufacturing, 38, 1592-1599.
• Demirtas, E.A., Gultekin, O.S. and Uskup, C. (2022). “A Case Study for Surgical Mask Production During the COVID-19 Pandemic: Continuous Improvement with Kaizen and 5S Applications”, International Journal of Lean Six Sigma, 14(3), 679-703.
• Ehie, I. and Sheu, C. (2005). “Integrating Six Sigma and Theory of Constraints for Continuous Improvement: A Case Study”, Journal of Manufacturing Technology Management, 16(5), 542-553.
• Gijo, E. V., Antony, J., Kumar, M., McAdam, R. and Hernandez, J. (2014). “An Application of Six Sigma Methodology for Improving the First Pass Yield of a Grinding Process”, Journal of Manufacturing Technology Management, 25(1), 125-135.
• Girmanová, L., Šolc, M., Kliment, J., Divoková, A. and Mikloš, V. (2017). “Application of Six Sigma Using DMAIC Methodology in the Process of Product Quality Control in Metallurgical Operation”, Acta Technologica Agriculturae, 20(4), 104-109.
• Goh, T.N. (2002). “The Role of Statistical Design of Experiments in Six Sigma: Perspectives of a Practitioner”, Quality Engineering, 14(4), 659-671.
• Kaoudom, N., Yimtrakarn, T. and Choomrit, N. (2019). “Using DMAIC Methodology to Reduce Defects in Sport Bar Products”, In IEEE sponsored 6th International Conference on Industrial Engineering and Applications (ICIEA), Tokyo, Japan, 852-855.
• Karamustafaoğlu, O. ve Sontay, G. (2018). “6-Sigma Yöntemine Dayalı Fen Öğretimi”, Güncel Yaklaşım ve Yöntemlerle Etkinlik Destekli Fen Öğretimi (Editör: Karamustafaoğlu, O, Tezel, Ö. ve Sarı, U.), Pegem Akademi, Ankara, 220-238.
• Kaushik, P., Khanduja, D., Mittal, K. and Jaglan, P. (2012). “A Case Study: Application of Six Sigma Methodology in a Small and Medium‐Sized Manufacturing Enterprise”, The TQM Journal, 24(1), 4-16.
• Kumar, M., Antony, J., Antony, F. J. and Madu, C.N. (2007). “Winning Customer Loyalty in an Automotive Company Through Six Sigma: A Case Study”, Quality and Reliability Engineering International, 23(7), 849-866.
• Kumaravadivel, A. and Natarajan, U. (2013). “Application of Six-Sigma DMAIC Methodology to Sand-Casting Process with Response Surface Methodology”, The International Journal of Advanced Manufacturing Technology, 69(5-8), 1403-1420.
• Lingam, D., Ganesh, S. and Ganesh, K. (2015). “Cycle Time Reduction for T-shirt Manufacturing in a Textile Industry Using Lean Tools”, In IEEE sponsored 2nd international conference on innovations in information, embedded and communication systems (ICIIECS), New York, USA, 2-7.
• Matthew, S. (2011). “Putting DMAIC of Six Sigma in Practice,” International Journal of Business and Social Science, 2(5), 115-117.
• Monica, S. and Beata, M. (2018). “Using Six Sigma DMAIC to Improve the Quality of the Production Process: A Case Study”, Procedia-Social and Behavioral Science, 238, 590-596.
• Mukhopadhyay, A.R. and Ray, S. (2006). “Reduction of Yarn Packing Defects Using Six Sigma Methods: A Case Study”, Quality Engineering, 18(2), 189-206.
• Nagi, A. and Altarazi, S. (2017). “Integration of Value Stream Map and Strategic Layout Planning into DMAIC Approach to Improve Carpeting Process”, Journal of Industrial Engineering and Management (JIEM), 10(1), 74-97.
• Natarajan, M., Senthil, V., Devadasan, S.R., Vijay Mohan, N. and Sivaram, N.M. (2013). “Quality and Reliability in New Product Development: A Case Study in Compressed Air Treatment Products Manufacturing Company”, Journal of Manufacturing Technology Management, 24(8), 1143-1162.
• Pepper, M.P. and Spedding, T.A. (2010). “The Evolution of Lean Six Sigma”, International Journal of Quality & Reliability Management, 27(2), 138-155.
• Prabu, K., Makesh, J., Raj, K.N., Devadasan, S.R. and Murugesh, R. (2013). “Six Sigma Implementation Through DMAIC: A Case Study”, International Journal of Process Management and Benchmarking, 3(3), 386-400.
• Prasad, M.M., Dhiyaneswari, J.M., Jamaan, J.R., Mythreyan, S. and Sutharsan, S.M. (2020). “A Framework for Lean Manufacturing Implementation in Indian Textile Industry”, Materials Today: Proceedings, 33, 2986-2995.
• Pugna, A., Negrea, R. and Miclea, S. (2016). “Using Six Sigma Methodology to Improve the Assembly Process in an Automotive Company”, Procedia-Social and Behavioral Sciences, 221, 308-316.
• Putri, N.T., Hidayat, B., Fatrias, D. and Indrapriyatna, A.S. (2018). “Reducing Bag Defects Using Six Sigma Methodology: A Case Study in a Cement Industry”, In IEEE sponsored 7th International Conference on Industrial Technology and Management (ICITM), Oxford, UK, 11-16.
• Ryan, T.P. (2005) “Taguchi's Quality Engineering Handbook”, Journal of Quality Technology, 37(3), 249-251.
• Saleeshya, P.G., Raghuram, P. and Vamsi, N. (2012). “Lean Manufacturing Practices in Textile Industries – A Case Study”, International Journal of Collaborative Enterprise, 3(1), 18-37.
• Singh, J., Singh, H. and Pandher, R.P.S. (2017). “Role of DMAIC Approach in Manufacturing Unit: A Case Study", Journal of Operations Management, 16(4), 52-67.
• Smętkowska, M. and 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.
• Sokovic, M., Pavletic, D., and Fakin, S. (2005). “Application of Six Sigma Methodology for Process Design”, Journal of Materials Processing Technology, 162, 777-783.
• Sontay, G., and Karamustafaoğlu, O. (2017). “A New Method for the Science Teaching: 6-Sigma Method”, Journal of Education and Practice, 8(32), 13-19.
• Srinivasan, K., Muthu, S., Prasad, N.K. and Satheesh, G. (2014). “Reduction of Paint Line Defects in Shock Absorber Through Six Sigma DMAIC Phases”, Procedia Engineering, 97, 1755-1764.
• Uluskan, M. and Oda, E.P. (2020), "A thorough Six Sigma DMAIC Application for Household Appliance Manufacturing Systems: Oven Door-Panel Alignment Case", The TQM Journal, 32(6) ,1683-1714.
• Uluskan, M. (2016). “A Comprehensive Insight into the Six Sigma DMAIC Toolbox”, International Journal of Lean Six Sigma, 7(4), 406-429.
• Uluskan, M. (2019). “Design of Experiments Based Six Sigma DMAIC Application: Electrostatic Powder Coating Process”, in IEEE sponsored 3rd International Symposium on Multidisciplinary Studies and Innovative Technologies (ISMSIT), Ankara, Türkiye, 1-11.
• Utkun, E. and Güner, M. (2012). “A Rationalization Study About Six-Step Method Systematic and Lean Manufacturing Technique for the Apparel Industry”, Textile and Apparel, 22(2), 152-158.
• Yetimler, G. (2018), “Six Sigma Approach for Launch of Production and an Application” (in Turkish), Master of Science Thesis, Eskisehir Osmangazi University, Graduate School of Natural and Applied Sciences, Eskisehir.