Data needs to be recorded sequentially. Accounting and finance people call this technique a time series. Whenever one collects data, either by counting or measuring, record 100% of the data in sequential order. The process flow diagram describes an efficient, economical, and thorough path towards six sigma improvements. This process has repeatedly demonstrated its capacity for productivity, quality, information and breakthrough improvements.

ANALYSE: This phase involves the data analysis for identification of parts of process which affect the quality of the problem. There are a number of statistical tools available such as Hypothesis Testing, Regression Analysis and historical Design of PFMEA, Box Plot,t test, ANOVA, Correlation, Regression.

IMPROVE: This phase adds to the process to find a permanent solution to the problem. This may involve better forecasting, better scheduling, better procedures or equipment.

CONTROL: This phase involves the process of establish ongoing process controls to avoid the problem recurring by implementing Control Charts, assigning clear process ownership and documenting the improved workflow which used to solving the problem by putting in the right procedures and management statistics.

Case Study 1:

• Define : Annual customer complaints were well over 10%
• Measure: Major faults that occurred in Final product were analysed by using Histogram for prioritization.

Defects per unit (DPU) = total defects/total units
Defects per million opportunities = DPU X 1,000,000
Or, DPMO = (total defects/total opportunities) X 1,000,000
Defects% =(total defects/total opportunities) X 100
Yield% = 100 – (defects%)
Process Sigma =NORMSINV[1–total defects /total opportunities )] +1.5

• Analyse : PFMEA tool was used to find out the RPN value and action taken accordingly.It is a systematic analysis of potential failure modes aimed at preventing failures or errors.

An PFMEA is a two-phase process

- First the potential failure modes and corrective actions are identified.
- Then after the corrective actions are implemented, process is re-
evaluated to determine if the result is acceptable.

Improve:

Various suggestions for improvements were given. Some of the major ones were:

1. Proper Training was imparted to the Quality Inspector
2. Quality Awareness Program was conducted for Operators and Checkers
3. A suitable Quality Manual was prepared for the unit
4. Work Instructions were developed and issued to each of the departments
5. “Quality Defects Identifiable Boards” were put up across the departments

• Introduction of Quality Checking Systems or Formats and constant monitoring by a trained Quality Inspector has brought about drastic reduction in quality defects level.

• There is a significant decrease in Defects Per Million Opportunities (DPMO) in both Jacquard (65.5% reduction) seat covers before and after quality system implementation.

• The Process Sigma level has also improved for both the product types. In percentage terms, there is a jump in Process Sigma level by 22.48% in Jacquard product.

• Estimated increased sale in Jacquard is Rs. 5,31,028/- per month.

• It can be aptly stated that this kind of a change is evident only after establishing foolproof measures to check quality and by creating its awareness among the middle management, workers and checkers.

• Control : Create control Chart and control plan