Abstract

Six Sigma is a management philosophy developed by Motorola, USA. This method is a project-driven approach of management to improve in organization’s products, their services and processes by continually reducing the defects. Statistically, the term Six Sigma is defined of having less than 3.4 defects per million opportunities and a success rate of 99.9997%, where sigma is a term used to represent the variation about the process average. Syntron LTD is manufacturer of high quality Polypropylene bags. During last few years, high rejection rate of polypropylene bags at Syntron LTD raised the eyebrows of both Customers and top management of the factory. This high Rejection Rate was reducing their profit margins and was earning a bad name for them in market as well. It was a Quality oriented problem. This problem was conveyed to National University of Sciences and Technology (Nust), Islamabad, Pakistan in order to conduct study to reduce this Rejection Rate. A research tour was arranged by School of Mechanical and Manufacturing Engineering (SMME), Nust. After reviewing data by the research student (Mr. Hamad), a strong indication was seen towards the DMAIC (Define-Measure-Analyze-Improve-Control) methodology of Six Sigma which appeared the only best possible solution to the problem. The Six Sigma was successfully implemented and there was an appreciable 50% reduction in rejection rate of Polypropylene bags. The calculated savings from the research study was 11.5 million per year.