Modelo de referência para estruturar o Seis Sigma nas organizações

Este artigo apresenta o modelo de referência para estruturar o Seis Sigma, o qual é resultante da incorporação de teorias que contribuem para aumentar o potencial estratégico do Seis Sigma no sentido de incrementar o desempenho organizacional. em sua proposta, o modelo de referência engloba um direcionamento sobre certos requisitos primordiais para o sucesso do programa Seis Sigma. A base teórica de sustentação do modelo de referência foi construída a partir de estudos sobre a influência dos seguintes fatores: orientação estratégica e alinhamento estratégico; medição e gerenciamento do desempenho organizacional; uso de estatística (pensamento estatístico); capacitação/especialização de pessoas; implementação e gerenciamento de projetos; e uso de tecnologia de informação. Complementando a proposição do modelo, o artigo traz evidências empíricas acerca da contribuição dos fatores identificados na formulação do modelo de referência, expondo resultados decorrentes de estudos de caso realizados em quatro subsidiárias brasileiras de multinacionais de grande porte. A análise dos dados forneceu evidências positivas de que os fatores mencionados influenciam de forma efetiva o sucesso e a consolidação do Seis Sigma nas empresas estudadas.

Análise do processo de gestão de portfólio de projetos seis sigma em indústrias brasileiras do setor automotivo

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Verificação da eficiência da metodologia Seis Sigma na redução da divergência de estoque em uma indústria de condutores de fluídos

This work was developed in order to reduce the discrepancy found between the stock data of an item in the system and the amount found physically in stock in the company presented on this study case. Therefore, this paper makes a study on system of information that can assist in the collection, control and manipulation of data regarding the company's stock. It is very important to do the inventory management, so we can control the level of this sub-product to meet sales orders and production. In the study discussed below, we used the Six Sigma methodology to identify points that had flaws in the process and thus improve their work where the results show grater process control and provide a reliable database to the point where no further problems of lack of components in stock

Projeto DMAIC com ferramentas Seis Sigma para redução de sucata em uma multinacional do ramo de acessórios automobilísticos

In this era of globalization, with fierce competition in the labor market, using the reduction cost strategy and resources optimization, has become a competitive advantage. In this graduation study, it will be exposed in form of case study the DMAIC project (Define Measure Analyze Improve Control) execution, using of Six Sigma's tools, statistical and quality knowledge, with intent of analyze, improve and control the processes of a selected problem, always demonstrating good practice of methodologies. In an auto parts multinational branch, It was identified a high scrap rate in one of his production lines. This work will study this problem to improve their processes and ensure that these improvements are perpetual. As a result, reached the stipulated goals, increasing Corporation's Intellectual, thereby providing a competitive advantage

A Construction Management Framework for Mass Customisation in Traditional Construction

A Mass Customisation model is discussed as a competitive positioning strategy in the marketplace adding value to the customer’s end-use. It includes the user as part of the construction process responding to the customer’s demands and wishes. To the present day, almost all proposals for Mass Customisation have been focused on the design phase and single family houses. The reality is that the processes carried out in the work execution are so inefficient that the costs of the Mass Customisation models are assumed by the customer and they do not offer solutions that support the change management. Furthermore, this inefficiency often makes Mass Customisation unfeasible in terms of deadlines and site management. Therefore, the present proposal focuses on achieving the paradigm of Mass Customisation in the traditional residential construction complementary to the existing proposals in the design phase. All this through the proposal of a framework for the integral management in the work execution, which will address change management introduced by the users offering an efficient and productive model that reduces costs in the process. This model will focus on the synergy between different strategies, techniques and technologies currently used in the construction management (such as Lean Construction or Six Sigma), together with, other strategies and technologies that have proven to be valid solutions in other fields (such as Business Process Management, Service Oriented Architecture, etc.).

A survey of continuous improvement practices in the United Kingdom and Mexico

With the advent of globalisation companies all around the world must improve their performance in order to survive. The threats are coming from everywhere, and in different ways, such as low cost products, high quality products, new technologies, and new products. Different companies in different countries are using various techniques and using quality criteria items to strive for excellence. Continuous improvement techniques are used to enable companies to improve their operations. Therefore, companies are using techniques such as TQM, Kaizen, Six-Sigma, Lean Manufacturing, and quality award criteria items such as Customer Focus, Human Resources, Information & Analysis, and Process Management. The purpose of this paper is to compare the use of these techniques and criteria items in two countries, Mexico and the United Kingdom, which differ in culture and industrial structure. In terms of the use of continuous improvement tools and techniques, Mexico formally started to deal with continuous improvement by creating its National Quality Award soon after the Americans began the Malcolm Baldrige National Quality Award. The United Kingdom formally started by using the European Quality Award (EQA), modified and renamed as the EFQM Excellence Model. The methodology used in this study was to undertake a literature review of the subject matter and to study some general applications around the world. A questionnaire survey was then designed and a survey undertaken based on the same scale, about the same sample size, and the about the same industrial sector within the two countries. The survey presents a brief definition of each of the constructs to facilitate understanding of the questions. The analysis of the data was then conducted with the assistance of a statistical software package. The survey results indicate both similarities and differences in the strengths and weaknesses of the companies in the two countries. One outcome of the analysis is that it enables the companies to use the results to benchmark themselves and thus act to reinforce their strengths and to reduce their weaknesses.

A modified quality control method for manufacturing process in mask industry

Masks are widely used in different industries, for example, traditional metal industry, hospitals or semiconductor industry. Quality is a critical issue in mask industry as it is related to public health and safety. Traditional quality practices for manufacturing process have some limitations in implementing them in mask industries. This paper aims to investigate the suitability of Six Sigma quality control method for the manufacturing process in the mask industry to provide high quality products, enhancing the process capacity, reducing the defects and the returned goods arising in a selected mask manufacturing company. This paper suggests that modifications necessary in Six Sigma method for effective implementation in mask industry.

Comparative study of DFSS in product and service innovation

Six sigma has proven itself as a major quality initiative in the last two decades. It is a philosophy which provides a systematic approach to applying numerous tools in the framework of several quality improvement methodologies. The most widely used six sigma methodology is DMAIC, which is best suited for improving existing processes. In order to build quality into the product or service, a proactive approach like Design for Six Sigma (DFSS) is required. This paper provides an overview of DFSS, product innovation, and service innovation. The emphasis is on comparing how DFSS is applied differently in product and service innovation. This paper contributes by analysing the existing literature on DFSS in product and service innovation. The major findings are that the DFSS approach in services and products can be differentiated along the following three dimensions: methodology, characteristics, and technology.

Development of a high-speed sensing and detection system for automatic removal of packages with leaky seals from a high-speed food processing and packaging line

Contamination of packaged foods due to micro-organisms entering through air leaks can cause serious public health issues and cost companies large amounts of money due to product recalls, consumer impact and subsequent loss of market share. The main source of contamination is leaks in packaging which allow air, moisture and microorganisms to enter the package. In the food processing and packaging industry worldwide, there is an increasing demand for cost effective state of the art inspection technologies that are capable of reliably detecting leaky seals and delivering products at six-sigma. The new technology will develop non-destructive testing technology using digital imaging and sensing combined with a differential vacuum technique to assess seal integrity of food packages on a high-speed production line. The cost of leaky packages in Australian food industries is estimated close to AUD $35 Million per year. Contamination of packaged foods due to micro-organisms entering through air leaks can cause serious public health issues and cost companies large sums of money due to product recalls, compensation claims and loss of market share. The main source of contamination is leaks in packaging which allow air, moisture and micro-organisms to enter the package. Flexible plastic packages are widely used, and are the least expensive form of retaining the quality of the product. These packets can be used to seal, and therefore maximise, the shelf life of both dry and moist products. The seals of food packages need to be airtight so that the food content is not contaminated due to contact with microorganisms that enter as a result of air leakage. Airtight seals also extend the shelf life of packaged foods, and manufacturers attempt to prevent food products with leaky seals being sold to consumers. There are many current NDT (non-destructive testing) methods of testing the seal of flexible packages best suited to random sampling, and for laboratory purposes. The three most commonly used methods are vacuum/pressure decay, bubble test, and helium leak detection. Although these methods can detect very fine leaks, they are limited by their high processing time and are not viable in a production line. Two nondestructive in-line packaging inspection machines are currently available and are discussed in the literature review. The detailed design and development of the High-Speed Sensing and Detection System (HSDS) is the fundamental requirement of this project and the future prototype and production unit. Successful laboratory testing was completed and a methodical design procedure was needed for a successful concept. The Mechanical tests confirmed the vacuum hypothesis and seal integrity with good consistent results. Electrically, the testing also provided solid results to enable the researcher to move the project forward with a certain amount of confidence. The laboratory design testing allowed the researcher to confirm theoretical assumptions before moving into the detailed design phase. Discussion on the development of the alternative concepts in both mechanical and electrical disciplines enables the researcher to make an informed decision. Each major mechanical and electrical component is detailed through the research and design process. The design procedure methodically works through the various major functions both from a mechanical and electrical perspective. It opens up alternative ideas for the major components that although are sometimes not practical in this application, show that the researcher has exhausted all engineering and functionality thoughts. Further concepts were then designed and developed for the entire HSDS unit based on previous practice and theory. In the future, it would be envisaged that both the Prototype and Production version of the HSDS would utilise standard industry available components, manufactured and distributed locally. Future research and testing of the prototype unit could result in a successful trial unit being incorporated in a working food processing production environment. Recommendations and future works are discussed, along with options in other food processing and packaging disciplines, and other areas in the non-food processing industry.

Reducing bubble defect on the outsole production process in the footwear manufacturing industry

The purpose of this study is to discover the significant factors causing the bubble defect on the outsoles manufactured by the Case Company. The bubble defect occurs approximately 1.5 per cent of the time or in 36 pairs per day. To understand this problem, experimental studies are undertaken to identify various factors such as injector temperature, mould temperature; that affects the production of waste. The work presented in this paper comprises a review of the relevant literature on the Six Sigma DMAIC improvement process, quality control tools, and the design of the experiments. After the experimentation following the Six Sigma process, the results showed that the defect occurred in approximately 0.5 per cent of the products or in 12 pairs per day; this decreased the production cost from 6,120 AUD per month to 2,040 AUD per month. This research aimed to reduce the amount of waste in men’s flat outsoles. Hence, the outcome of research presented in this paper should be used as a guide for applying the appropriate process for each type of outsole.

A importância da gestão de resíduos sólidos na redução de custos da não qualidade.

A presente dissertação visa analisar a importância da gestão dos resíduos sólidos industriais em uma indústria petroquímica e o uso da metodologia Seis Sigma na redução dos custos da qualidade associados à geração de resíduos sólidos e poluição ambiental. A Petroflex, fundada em 1962, situada em Campos Elíseos Duque de Caxias / RJ, é a maior fabricante de borracha sintética da América Latina e uma das primeiras empresas do Brasil e se certificar nas normas ISO. Os processos produtivos de obtenção da borracha sintética são potencialmente poluidores, todas as suas atividades provocam a geração de toneladas de resíduos sólidos. A Petroflex iniciou na década de 1990 seus esforços para reverter um quadro de degradação ambiental e uma cultura de desperdício. A partir de 2004, a Petroflex necessitou de uma nova concepção para priorização das suas ações e tomadas de decisões. A Metodologia Seis Sigma foi a escolhida para sustentar o novo salto de desenvolvimento da empresa e em 2008 a empresa alinhou a Seis Sigma ou Gerenciamento de Resíduos Sólidos. O uso da metodologia Seis Sigma, as ações tomadas e os resultados alcançados, bem como, a realização de um projeto em uma das unidades da Petroflex, que levou a criação de um manual de gestão de resíduos sólidos, serão apresentados nos capítulos dessa dissertação, que buscou pesquisas bibliográficas, eletrônicas e documentais para ilustrar os conceitos deste tema de grande importância para sociedade.

6Sigma在系统集成过程中的应用

6Sigma是实现过程控制和持续改进的有效方法,本文针对复杂系统集成过程管理存在的问题,分析了6Sigma在系统集成过程管理中应用的可行性,提出了一种基于6Sigma的系统集成过程模型.该模型具有信息及时反馈、过程持续改进、提高质量和降低成本的特点,在项目中得到应用并取得明显效果.

Risk mitigation framework for a robust design process

The increasing complexity of new manufacturing processes and the continuously growing range of fabrication options mean that critical decisions about the insertion of new technologies must be made as early as possible in the design process. Mitigating the technology risks under limited knowledge is a key factor and major requirement to secure a successful development of the new technologies. In order to address this challenge, a risk mitigation methodology that incorporates both qualitative and quantitative analysis is required. This paper outlines the methodology being developed under a major UK grand challenge project - 3D-Mintegration. The main focus is on identifying the risks through identification of the product key characteristics using a product breakdown approach. The assessment of the identified risks uses quantification and prioritisation techniques to evaluate and rank the risks. Traditional statistical process control based on process capability and six sigma concepts are applied to measure the process capability as a result of the risks that have been identified. This paper also details a numerical approach that can be used to undertake risk analysis. This methodology is based on computational framework where modelling and statistical techniques are integrated. Also, an example of modeling and simulation technique is given using focused ion beam which is among the investigated in the project manufacturing processes.