Uploaded by Sayali Ketkar

Implementation of Lean Six Sigma in Manufacturing Process

Karan Bhagat – 17BM60042
This six sigma project aims to improve the manufacturing of a semiconductor company which was focused on
manufacturing circuit cartridge for inkjet printers
One of the major issues was that the circuits were tested in the final stage for any defects in order to approve or reject
The six sigma methodology is focused on continuous improvement which minimizes defects and variation towards an
achievement of 3.4 defects per million opportunities
Once a project or goal is defined, the organization follows the disciplined six sigma process that’s defined by five
1. Define – in this step the problem statement is defined and all the parameters are listed
2. Measure - measure existing systems to learn what can be considered a baseline or benchmark, among other things.
3. Analyse - identify ways to eliminate defects. This can be done in a variety of ways, including statistical analysis to
determine the root cause of an issue.
4. Improve - seek optimal solutions, then develop and test the plan of action for improving a process or goal.
5. Control - The Control step can be ongoing—an organization may modify operating instructions, policies, or procedures
to help prevent future defects.
The implementation of this project has been considered as successful because the critical factor
for the process were found and controlled
The base line of the project was 3.35 sigma level and the gain 0.37 sigma that represents the
elimination of 1.88% of nonconforming units or 18,788 ppm’s
Also, the maintenance preventive program was modified to achieve the goal stated at the
beginning of the project.
It is important to mention that the organization management was very supportive and
encouraging with the project team.
Finally, six sigma implementation can be helpful in reducing the nonconforming units or
improving the organization quality and personal development.