Abstract

Improvements are required in any industry to increase the productivity by decreasing the defects
in any process and also remove the overall waste produced during any production inside the manufacturing facility. There are many process improvements techniques available for identify the problem causing factors for defects and one of the most famous techniques is Six Sigma technique which is widely used to identify the real problem causing factors by use of different tools such as DMAIC which is nothing but Define, Measure, Analyze, Improve and Control. In this particular plastic manufacturing industry, the main problem was time required for tool changeover was very large which result in long waiting time for production as different dies and mold where required for production of fuel tanks. The real reason behind delay in tool or die changeover was required to be found as the overall production was decreasing which resulted in lot of customer unsatisfaction and also company could not reach its daily production targets. By use of Six Sigma tools main aim is to find factors causing time delay in tool and dies change over and to find factors which will solve the problem in analyze phase. It was identified that by SMED i.e. Single Minute Exchange of Dies technology can be used to improve total time required for tools, dies and molds changeover which will increase efficiency by 50%. In the process of Six Sigma tools used in define phase are project charter and SIPOC then cause and effect diagram, pareto chart, and brainstorming tools are used in measure phase, in analyze phase run chart and process capability analysis is used and in improve phase by use of run chart and process capability analysis it is made sure that process is really improved.