Abstract:
Purpose- The purpose of this paper is to explore the role of Six Sigma in reducing the rejection reduction
of polypropylene bags in a certain manufacturing sector via implementation of its DMAIC methodology.
The paper also highlights the financial savings achieved with the implementation of Six Sigma
methodology.
Design/methodology/approach- The Define-Measure-Analyze-Improve-Control (DMAIC) approach of
Six Sigma methodology was used for achieving the research objective. A step-by-step procedure was
followed and implemented in order to control the identified process variation in the manufacturing process
of the product.
Findings- A 50% reduction in rejection rate of polypropylene bags was calculated after the successful
implementation of Six Sigma. The problem area was identified in the Define phase. The extent of the
problem was measured in the Measure phase. Key process input variables were identified in the Analyze
phase. Design of Experiments was used in the Improve phase to obtain the optimum settings for the
process. Moreover, a control plan was prepared in the control phase to sustain the achieved
improvements. The reduction in rejection rate provided a significant financial benefit by improving the
strength of the bags. Furthermore, improved quality of the polypropylene bags created Customer
Satisfaction with an increased profit margin.
Originality/Value- The paper explains a step-by-step approach to implement the DMAIC methodology of
Six Sigma.
Keywords Six Sigma, Manufacturing industries, Rejection rate, Quality Control
Paper type Research paper

Muhammad Hamad Sajjad

Affiliation

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Reduction in Rejection Rate of Polypropylene Bags via Six Sigma