Success Factors And Barriers To Six Sigma Implementation In Process Industry

Literature Review

In this report the topic of the discussion is the six sigma implementation in the process industry.  In the recent time the companies are using many improvement technologies. From the year of 1980 there has been a revolution in the process industries around the globe. The customer of the process industry became demanding in the recent time. And the industry had to satisfy the needs of the customers (Fan et al., 2015). In this report our main focus is on the process industry. The process industries managers faces several different issues. The sale is less and the cost are increasing because of the customer demands and their selection process. The process industry had to make sure that they will be able to generate profit in the market. They have to provide the products which are of high quality and provide efficient service for the customers of the process industry. To improve this the industry must focus on the two ways one way is the improving the efficiency of the operation and another way is the enhancement of the quality of the operation. In the recent time the companies are using several different type of quality programs for the customer satisfaction and reduction of cost (F?rat et al.,2017). Among the all programs that are in the market right now, the six sigma is the most applied and widely accepted. The six sigma is the quality enhancement program which is based on statistics. It helps the businesses and the industries to reduce the amount of waste and the poor quality costs. It also improved the efficiency and the effectiveness of the industry. These will lead to the customer satisfaction and implementation of these will increase the profitability of the industry. To eliminate the defect of the industries six sigma is also used.

In this literature review the topic of the review is about six sigma technologies. The purpose of the review is to capture the state of the six sigma and the current practices of the six sigma. The objective of this paper is to capture the state of the art in the six sigma and document the development by the literature review.

At the first time the company implemented some processes for the project improvement semantically (Sharma, Gupta and Saini 2018). As the experience is not enough and the capabilities of the employees are insufficient so that the company is afraid to implement the six sigma. Though the projects are successful because of this. In the literature review the search strategy is also will be discussed. The search strategy developed first by identifying the data sources that are relevant to the sources. The search is done by choosing the key words and the combinations that are possible, these are very significant to the six sigma. The six sigma concept takes a long range of the aspects and considers the necessary number of strings. These all are capture the all aspects that characterises the six sigma, like the methodology, techniques, tools, enablers, implementation and the issues. The keywords are related to each other and they have connection that also will be used. The search strategy will identify several publications. The all publication is checked and they are checked first by the abstract. Because the abstract contains the whole review and the scope of the. The details that are having vagueness will be excluded. There are many publications from which we are able to identify the streams of the six sigma. The first stream of the six sigma defines the statistical set of tools that are adopted for the management of the quality for the framework construction to improve the processes. The main goal is to improve the six sigma level of the measured performance which refers to the Critical to Quality that reflects the data quality and the customer satisfaction (Sin et al., 2015). The second stream defines the six sigma as the operational philosophy of the management that can be shared for the benefits of the customer, employees, shareholders ad for the suppliers. It is flexible, the application of the six sigma is not limited only to the manufacturing, and it can be extended to the all supply chain that includes the service provision. The six sigma is also known as the multifaceted, customer oriented, proactive, semantic, and structured to improve the quality and to reduce the cost. The third streams defines the six sigma as the culture of the business. This stream says that the six sigma success does not depends on the statistical tools but it also dependent on the commitment of the top management guarantees the employees involvement in the organization. The six sigma follows a top down approach that the detailed analysis demands, the decisions that are fact based and control plan that ensures the quality of the control process that is ongoing (Walters and Barneva 2017). The fourth definition of the sig sigma refers to the methodology of the analysis which uses for the methods that are scientific. The six sigma is very popular and used for the improved methodology. Six sigma is an extension which used for the quality improvement initiatives like the TQM (Total Quality Management) because of the same features between the six sigma method of measure, design, improve, analyse, control (DMAIC).

Objectives and Aims of Six Sigma Implementation

The tools of the six sigma is followed by the well-structured method which is called the DMAIC. The DMAIC id implemented to the process industry for solving the problem of the industry. If the problem of the process industry is clearly defined then the defect can be identified in the industry. The DMAIC is also helps to make the decisions. The objective of the six sigma is to maintain the product quality in order to fulfil the customer satisfaction. It tackles the benefit of the project and for the reduction of the variation. In the process industry it uses the improvement method of the statistics to reduce the defects in the services and products. The goals of any project is defined that how the improvements is going through the product to meet the satisfaction of the customers. In many cases the objective is turn to the perspective of the business. Irrespective of the goals the processes that is implemented is more or less same.

The main aim of the six sigma in the process industry is to mitigate the inefficiency and the waste in the process industry, which will further lead to the satisfaction of the customers. The six sigma follows a well-structured methodology and the roles of the participants are described in the process industry.

Another goal of the six sigma in the process industry is to increase the amount of the profit in the industry. The profit must be generated with keeping in mind about the customer loyalty.

Quality improvement is another objective of the six sigma implementation. The term that is sigma is related to the metric that is used for the rate of the manufacturing in process engineering. Because of the six sigma the produce product is 99.99% error free.

The common and the known definition of the six sigma is that it is mainly a set of tools and some techniques which is used for the improvement of the process and to solve the problem. Over the time the definition of the six sigma has gone through several revolution. The six sigma is a programme of improvement that gain the attention in the recent years. The six sigma is mainly implemented on the DMAIC phases. The phases of the DMAIC are described below:

This is the first phase of the DMAIC. In this phase the top management are identify the problem as per the feedback from the customer, mission and the strategy of the company. In this phase the requirements of the customers are defined and the goals is set.

Six Sigma Method

The measurement phase is the key of the transition step on the road of the six sigma. That helps the projects, to identify the problem and then search for the cause of the problem and that will be the objective for DMAIC step of analyse (Fong 2016).  Then the project team needs to validate the processes and to refine the goals and the key steps and the inputs are measured.

In this phase, the team of the project should use the tools of the data analysis and the analysis of the process techniques for the identification and to verify the root of the problem. The team needs to identify the vital cause roots and to validate the hypothesis.

The main objective of the improve stage is to identify and then implement the solutions which mitigates the problems cause and reduce the variation in a process. Or to prevent the problem that is related with the recurring. So the team of the project needs to develop the ideas to remove the roots of the causes, test the solutions and to standardize the solution (Kamble and Kumar 2017).

In this phase once the complete of the improvement and the documentation of the result, continuous measurement of the process performance according to the routine, and the adjustment of the operation. Without the effort of the controls, the improved processes that will revert to the previous phase.

The result of the application of the six sigma will lead to the attainment of the superior performance in the field of finance and other fields. This can be done by the implementation of the new ideas and new processes. This can be done by the accepting and implementing the new processes (Basios and Loucopoulos 2017). The implementation of the six sigma in the process industry helps in the increasing of the efficiency and helps in the providing of the effective solutions for taking the organization to a better place. The implementation of six sigma technique in the process industry helps in attainment of new ideas which provides the organization with competitive advantage. The result of the implementation of six sigma helps in improving the process and helps in the betterment of the processes of the process industry. The six sigma results in providing a better structure for the management by the implementation of different modules (Furterer 2016). This will help in the better team work and will help in the increase of productivity individually and as a team as a whole.

Define Phase

The outcome of the implementation of the six sigma in the process industry is that it helps in a broad way to a large number of industry. For instance, in Johnson Controls the six sigma process helps in reduction of defect by around seventy percent. It also helps in the reduction of cost by 8lacs dollar per year. The cost of the processing was saved 9.43lacs dollar per year (Hylton 2017). The outcome of the six sigma contributes in the better quality management of the products. Six sigma helps in the decrease in the variation of the process. The six sigma contributes in making the error to near zero. It also helps in the increase of the stability of the organization. For instance in case of Motorola, the organization was successful in saving around 1.5billion dollar. It saved this amount in the first ten years of the implementation of six sigma.

As far as relevance is concerned, the six sigma contributes for the better planning and creation of the structure of the organization (Pyzdek and Keller 2014). There are certain certifications that are offered by six sigma makes the six sigma process better process than others. Six sigma also provide training to the employees for the creation of better ideas in order to take the organization to a better place. The people with the training of sig sigma may contribute in better analysing, improving and measure the control that are required for the project. For the organization where there is necessity of maintenance of large communication channel and large management structure, six sigma may contribute largely towards the profit of the organization. The six sigma started as a manufacturing unit, which has developed to different industries in the recent times. In all the field, the skills of six sigma may be applied (Srinivas and Sreedharan 2018). There are various organization which recognize the six sigma process to put the organization to a better place.

Conclusion:

From the above report it can be concluded that the six sigma has a significant effect on the process industry. In the above report it can be seemed the six sigma if first invented in the year 1980 and after the year this had gone through several revolution (Prashar 2014). We already know the customer of the process industry are becoming demanding day by day. The main focus of the report is to show the implementation of the six sigma in the phases of the DMAIC. In the above report we have seen the research questions that what are the barriers and the advantage of the six sigma that is implemented to the DMAIC phases. The methods of the DMAIC is described in the above report that how the each process works in the each phases of the DMAIC. From the above report it can be seen that the six sigma is mainly the tool which is based on the statistics. The six sigma provide lot of benefit to the company. The efficiency and the effectiveness of the company is increased and improved by the six sigma. The customer satisfaction is maintained by the six sigma and for this the industry that is implemented the six sigma gets highly benefitted from this and generate more revenue than before. After the implementation of the six sigma in the process industry got the ability to provide good products at low cost and good customer satisfaction.

References:

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