Structured problem solving: combined approach using 8d and six sigma case study

Abstract The current research study aimed to explore the utility of selected problem-solving tools and techniques in root-cause analysis to demonstrate their practical application. An experimental research design adopting a positivist empirical approach with a deductive strategy was followed to assess the effectiveness of a combined (8D & Six Sigma) problem-solving approach in reducing a high defects rate of a mixer shower assembly line. A novel application of the 8D framework in combination with Six Sigma and other analytical tools was found highly effective in reducing the reject rate from 11.84% to 0.11%. Successful identification of the root cause led to the implementation of permanent corrective action ensuring a long-term stable assembly process. The research study provided a problem-solving framework that was found effective in resolving a complex problem and implementing long-term corrective action in an assembly production line. However, this framework can be used in other industries. The research study provides a solution to a high number of leak rejects in a sub-assembly where "O-seals" are used between mating parts. It also provides analytical tools that were found highly effective during the problem-solving process.

[1]  Kazuhiro Esaki.  Common Management Process Model of New TQM Based on the Situation Analysis , 2016 .

[2]  Doina Morusca,et al.  Crashing the schedule in DCS validation pharmaceutical projects with lean six sigma and project management techniques : Case study and discussion , 2007 .

[3]  L. Oyewobi,et al.  Total quality management practices and organizational performance: the mediating roles of strategies for continuous improvement , 2019 .

[4]  Becki Meadows,et al.  Managing six sigma : a practical guide to understanding, assessing, and implementing the strategy that yields bottom-line success , 2001 .

[5]  Lizhi Wang,et al.  Leveraging Six Sigma with industrial engineering tools in crateless retort production , 2008 .

[6]  Uche Nwabueze.  An industry betrayed: the case of total quality management in manufacturing , 2001 .

[7]  Rakesh Agarwal,et al.  Managing outsourcing process: applying six sigma , 2008, Bus. Process. Manag. J..

[8]  Marián Bujna,et al.  Use of 8D Method to Solve Problems , 2013 .

[9]  Josim U. Ahmed.  Modern approaches to product reliability improvement , 1996 .

[10]  Joseph Moses Juran.  A history of managing for quality : the evolution, trends, and future directions of managing for quality , 1995 .

[11]  J. Bandyopadhyay,et al.  Six Sigma Approach to Quality and Productivity Improvement in an Institution for Higher Education in the United States , 2007 .

[12]  Sérgio Sousa,et al.  The 8D Methodology: An Effective Way to Reduce Recurrence of Customer Complaints? , 2010 .

[13]  Rebecca Simmons.  Book Review: Introduction to 8D Problem Solving: Including Practical Applications and Examples , 2018 .

[14]  O. John,et al.  Employability in the 21st Century: Complex (Interactive) Problem Solving and Other Essential Skills , 2015, Industrial and Organizational Psychology.

[15]  Mukesh Doble.  Six Sigma and chemical process safety , 2005 .

[16]  Mrigendra Nath Mishra.  Identify critical success factors to implement integrated green and Lean Six Sigma , 2018, International Journal of Lean Six Sigma.

[17]  Semyon Savransky,et al.  Engineering of Creativity: Introduction to TRIZ Methodology of Inventive Problem Solving , 2000 .

[18]  M. Leakey,et al.  Excavations in beds I and II, 1960-1963 , 1971 .

[19]  Rick L. Edgeman,et al.  Six Sigma and Business Excellence: Strategic and Tactical Examination of IT Service Level Management at the Office of the Chief Technology Officer of Washington, DC , 2005 .

[20]  Dwayne Spradlin,et al.  Are you solving the right problem? , 2016, IEEE Engineering Management Review.

[21]  Robert Phaal,et al.  A review of TRIZ, and its benefits and challenges in practice , 2013 .

[22]  Subrata Talapatra,et al.  Development of an Implementation Framework for Integrated Management System Based on the Philosophy of Total Quality Management , 2018 .

[23]  Chao-Ton Su,et al.  A systematic methodology for the creation of Six Sigma projects: A case study of semiconductor foundry , 2008, Expert Syst. Appl..

[24]  Alan Harrison,et al.  Deployment of Six Sigma methodology in Human Resource function: A case study , 2000 .

[25]  H. Peck,et al.  Risk management in military supply chains: Is there a role for six sigma? , 2006 .

[26]  Guangming Cao,et al.  A systemic view of organisational change and TQM , 2000 .

[27]  Peter C. Brewer,et al.  Near zero-defect accounting with Six Sigma , 2004 .

[28]  Adan Valles,et al.  Implementation of Six Sigma in a Manufacturing Process: A Case Study , 2009 .

[29]  N. Toth.  The oldowan reassessed: a close look at early stone artifacts , 1985 .

[30]  Victor Fey,et al.  Innovation on Demand: New Product Development Using TRIZ , 2005 .

[31]  Robert E. Cole,et al.  Learning from the Quality Movement: What Did and Didn't Happen and Why? , 1998 .

[32]  Ancuţa Păcurar.  Applications of Design for Manufacturing and Assembly , 2019 .

[33]  S. Vinodh,et al.  Deploying Lean Six Sigma framework in an automotive component manufacturing organization , 2016 .

[34]  A. Elshennawy,et al.  Implementation of TQM and lean Six Sigma tools in local government: a framework and a case study , 2005 .

[35]  Eric R. Ziegel,et al.  Handbook of Statistics 13: Design and Analysis of Experiments , 2000 .

[36]  Raid Al-Aomar,et al.  A simulation-based DFSS for a lean service system , 2006 .

[37]  Richard C. Whitfield,et al.  Improving integrated circuits assembly quality ‐ a case study , 1996 .

[38]  R. Andersson,et al.  Similarities and differences between TQM, six sigma and lean , 2006 .

[39]  John Clark,et al.  NewYork‐Presbyterian Hospital uses Six Sigma to build a culture of quality and innovation , 2006 .

[40]  Ellen Domb,et al.  Simplified TRIZ: New Problem-Solving Applications for Engineers and Manufacturing Professionals , 2002 .

[41]  J. Šebestová.  The Conflict between Strategic Method Application and Theoretical Knowledge in Small and Medium Sized Companies: The Case of the Czech Republic , 2016 .

[42]  R. Boaden.  What is total quality management...and does it matter , 1997 .

[43]  Taho Yang,et al.  Six-Sigma Project Selection Using National Quality Award Criteria and Fuzzy Multiple Criteria Decision-Making Method , 2008, 2008 4th International Conference on Wireless Communications, Networking and Mobile Computing.

[44]  Anna Olszewska.  Research issues undertaken within quality management – the overview of selected literature , 2017 .

[45]  Bernd-Arno Behrens,et al.  Complaint management using the extended 8D-method along the automotive supply chain , 2007, Prod. Eng..

[46]  Krishna Arul,et al.  Six Sigma for Software Application of Hypothesis Tests to Software Data , 2004, Software Quality Journal.