Title: Application of Six Sigma methodology in reducing oil consumption in a manufacturing process

Authors: Johny Scaria; Jose Joseph M

Addresses: Department of Statistics, Nirmala College, Muvattupuzha, Kerala – 686661, India ' Department of Statistics, St. Peter's College Kolenchery, Kerala – 682 311, India

Abstract: This article discusses the successful application of Six Sigma define-measure-analyse-improve-control (DMAIC) methodology in an engineering industry for reducing the oil consumption during a machining process. As the cutting oil prices are very high, excessive consumption of cutting oil will significantly increase production cost. This will even affect the profitability and competitiveness of the organisation. Hence, Six Sigma DMAIC methodology was applied to this process for reducing the oil consumption. The potential causes of high oil consumption were identified through a brainstorming session. Based on the analysis of the data on these causes, root causes were identified and solutions were implemented. As a result of this study, the oil consumption was reduced by 40%, which was a remarkable achievement for the organisation.

Keywords: six sigma; DMAIC; sigma level; cause and effect diagrams; brainstorming; risk assessment; cause validation plan; regression analysis; control charts; matrix plot; oil consumption; manufacturing industry; machining processes; cutting oils.

DOI: 10.1504/IJBEX.2016.079255

International Journal of Business Excellence, 2016 Vol.10 No.4, pp.476 - 487

Received: 28 Jan 2015
Accepted: 26 Feb 2015
Published online: 26 Sep 2016 *

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