Track: Six Sigma

Abstract

Six Sigma is a well-structured methodology that helps organizations to achieve their goals due to its role as a problem-solving technique. This research discusses the application of the Six Sigma methodology in home appliance industrial Company in Egypt. The paper follows the Six Sigma DMAIC methodology (Define, Measure, Analysis, Improve, and Control) to systematically identify and define the root cause(s) of defects and to provide a reliable solution to reduce/eliminate them. Moreover, the use of the design of experiment (DOE) and the regression analysis have permitted to determine any existing correlation between the measurable causes and the increase in defects quantity and to identify the optimum temperature of the aluminum molten metal. The analysis of Six Sigma (DMAIC) methodology and the statistical analysis (DOE and regression analysis) determined that the aluminum molten metal temperature has a significant impact on the defects quantity of aluminum parts. After using the optimized temperature of the aluminum molten metal, the defects in aluminum products decreased from 10.49% to 6.1% and the Six Sigma level improved from 2.8 to 3.06. Therefore, Six Sigma can be considered a successful methodology in reducing defects and consequently increasing the cost savings and customer satisfaction.