Emerald | The TQM Journal

A case study: Application of Six Sigma methodology in a small and medium-sized manufacturing enterprise

Prabhakar Kaushik, Dinesh Khanduja, Kapil Mittal, Pawan Jaglan — 2012-01-06 00:00:00.0

Abstract

Purpose – Six Sigma within small and medium-sized enterprises (SMEs) is rapidly emerging as the new wave of change in Six Sigma. The purpose of this paper is to review the implications of applying Six Sigma methodology over the SMEs, taking a specific case of a bicycle chain manufacturing unit. The study could be a paradigm initiative towards high quality products and services at low cost for every SME. Design/methodology/approach – Based on the literature, this paper proposes a process flow chart to present a one-shot picture of the Six Sigma application in a bicycle chain manufacturing unit which falls in an SME environment. The methodology adopted is DMAIC methodology of Six Sigma, which had been mostly successful so far in large-scale industries. The methodology has been applied to reduce the bush rejection rate (bush is an important component of a cycle chain) by reducing defects inherent in the processes. The statistical techniques such as two sample t-test and process capability analysis have been used to establish the process capability before and after the Six Sigma application. Findings – This paper is an attempt to justify the highly useful role of quality management techniques like Six Sigma for SMEs which are normally presumed to be in the domain of large industries. In this paper, Six Sigma methodology has been applied to a small unit manufacturing bicycles chains with dwindling productivity levels. After applying Six Sigma it was found that the chain manufacturing firm can increase its profit by controlling high rejection rate of cycle chain bush. Application of Six Sigma project recommendation brought up the process sigma level to 5.46 from 1.40 by reduction in bush diameter variation in the process of bicycle chain bush manufacturing. This increase in sigma level is equivalent to monetary saving of Rs 0.288 million per annum, which is a noteworthy figure for an industry of such level. The success of this study paves the way to further extend the Six Sigma application to more such industries working in the SME environment. Originality/value – This paper provides documented evidence of Six Sigma implementation in a bicycle chain manufacturing unit which has been taken as representative of a small and medium-size industry. The study will yield a great value to academics, consultants, researchers and practitioners of Six Sigma.

Benefits of implementing management system standards: A case study of certified companies in the Pearl River Delta, China

W.M. To, Peter K.C. Lee, Billy T.W. Yu — 2012-01-06 00:00:00.0

Abstract

Purpose – The purpose of this paper is to explore the extent of implementing management system standards among ISO (and other) certified companies in the Pearl River Delta and its effect on the perceived benefits. Design/methodology/approach – A cross-sectional survey of certified companies was carried out using a self-administrated questionnaire. A total of 157 companies participated in the study. Findings – It was found that the majority of the responding companies implement more than one standardized management system, mostly adopting the quality management, environmental management, and occupational health and safety management systems (i.e. ISO9001, ISO14001, and OHSAS18001). Results show that companies certified to ISO9001 and ISO14001 gain more benefits than the others. Research limitations/implications – The study shows that companies implementing multiple management systems can have better corporate performance, product quality, and marketing edges than the others. The results indicate that different combinations of management systems give rise to different level of performance. Originality/value – There is a lack of empirical proof that more benefits will be gained when multiple management system standards are adopted. The paper addresses this short-coming and provides evidence that acquiring more system certifications will result in greater perceived benefits.

Adopting TQM approach to achieve customer satisfaction: A flour milling company case study

Yohanes Kristianto, Mian M. Ajmal, Maqsood Sandhu — 2012-01-06 00:00:00.0

Abstract

Purpose – The purpose of this paper is to present the results of a survey of customer satisfaction with regard to the strategy of total quality management (TQM) adopted in a wheat flour milling company. Design/methodology/approach – A survey was conducted to learn more about customer expectations and satisfaction. The respondents were all customers of a flour-based food processor. Quality function deployment (QFD) was applied to improve customer service performance by focusing on customer satisfaction, value and retention. Findings – The results show that customer satisfaction has increased steadily over a period of three years. The QFD approach helped to design a competitive product by aligning the company resources to customers’ needs. Research limitations/implications – The findings are limited to a specific food manufacturing company and for this reason they cannot be generalized to the whole in service sector. Further research is needed for other service companies. Practical implications – The findings may support manufacturing companies hoping to achieve customer satisfaction by focusing on TQM implementation efforts. Furthermore, companies can focus their efforts on improving the way in which they meet certain customers’ needs if these needs are more extensively related to a certain component of quality management. Originality/value – The paper presents evidence to managers of the value of implementing TQM strategy to effectively achieve customer satisfaction that ultimately leads to greater market share and profit maximization.

Eco-design in total environmental quality management: Design for environment in milk-products industry

George J. Besseris — 2012-01-06 00:00:00.0

Abstract

Purpose – The purpose of this paper is to propose a methodology that may aid in assessing ecological quality multi-trait screening through the use of simple and robust tools while exerting minimal effort in conducting trials and interpreting results. Design/methodology/approach – Response data for two popular site-monitoring environmental indicators, chemical oxygen demand (COD) and biochemical oxygen demand (BOD), are arranged by implementing an 8-run saturated orthogonal array proposed by Taguchi. Unreplicated data consolidation is performed through the Super-Ranking translation. This permits converting the two eco-traits to a single master response which becomes much easier to manipulate statistically. Distribution-free multi-factor contrasting provides the data reduction engine to filter-out non-active eco-design variables for a waste treatment unit in a large dairy-products plant. Findings – Environmental quality improvement is achieved by accumulating structured eco-data sets through an unreplicated-saturated L8(27) Taguchi design. Concurrent minimization of the two selected eco-responses, COD and BOD, promotes in a statistically significant fashion the quantity of incoming wastes, set at its minimum load, as the sole active eco-factor. Practical implications – Brief but robust experimentation is exploited in gaining information about the phenomenological behavior of environmental quality indicators, namely COD and BOD, in facilities that manage wastewater treatment. Design for environment is enforced through standard DOE planning schemes. Collected multi-metric eco-quality data are translated non-parametrically in an easy-to-comprehend manner that requires no assist from software aids while bypassing more statistical intensive techniques which may demand involvement of more experienced personnel. The methodology is accessible to any level of statistical competence seamlessly intertwined to optimization demands for rapid inference needs. Originality/value – The method mixes up three distinctive “design-and-analysis” elements in order to provide optimal solution in a design-for-environment project. The sampling capabilities of Taguchi's orthogonal arrays in concert with Super-Ranking transformation fuse multi-eco-characteristics to a single easy-to-handle master unitless eco-response. Order statistics tables recently published in terms of true probabilities have been adopted for supplying the proper cutoff points to be utilized for gauging against observed rank sums for an 8-run orthogonal array screening. Quality managers and environmental engineers who contribute routinely to continuous eco-improvement projects in their Total Environmental Quality Management (TEQM) program may find this approach attractive and viable en route to a typical industrial pollution prevention control deployment.

Approach for measuring health-related quality management

Yvonne Lagrosen, Ingela Bäckström, Håkan Wiklund — 2012-01-06 00:00:00.0

Abstract

Purpose – The purpose of this paper is to develop an approach to measuring health-related quality management based on earlier research on the connection between quality management and employee health. Design/methodology/approach – A questionnaire was developed and a research study was carried out at a manufacturing company. The constructs were tested for internal reliability using Cronbach's alpha tests. The dimensions’ correlations with employee health were checked using Pearson correlation. Findings – Three of the dimensions were correlated with the perception of employee health: “presence/communication” and “integrity” derived from leadership commitment, and “influence” derived from everybody's participation. These findings substantiate earlier studies indicating a relationship between visible, clear leadership and employee health. They are also in line with earlier findings of how the possibilities to influence their own work promote employee health and work ability. The paper provides a proposal as to how managers can proceed in the measurement and evaluation of quality management efforts related to employee health. Research limitations/implications – The research is conducted as a single research study in one industrial manufacturing company. Further research should be conducted in other organizations from different lines of business with the same conditions and in organizations with different conditions. Practical implications – This approach can be used by managers for gaining insight into underlying mechanisms in the organizational culture related to employee health from a quality management perspective. This could lead to improved employee well-being, satisfaction and motivation. It could be used as a first step for improvements when implementing health-related quality management “to break the ice” and it could be followed up by qualitative methods. Originality/value – Traditional ways of measuring health are rarely connected to quality management. Only requiring small resources, this approach to measuring health-related quality management can add to an understanding of underlying mechanisms.

Brands, quality badges and agricultural cooperatives: how can they co-exist?

Achilleas Kontogeorgos — 2012-01-06 00:00:00.0

Abstract

Purpose – The purpose of this paper is to examine different quality schemes and to determine how these could be combined by Agricultural Cooperatives into a brand development strategy designed not only to differentiate their products but also to enhance them with higher value added in the competitive landscape of the food industry. Design/methodology/approach – This paper will first address how brands have enclosed quality signs and even more, how consumers respond to it. Then, it will examine to what extent Greek Agricultural Cooperatives have developed brands for their products and whether they have used quality systems in their activities. Thus, the starting point in the paper's argument is that Agricultural Cooperatives have been slow to develop brands while consumers have been displaying a positive attitude towards these products. Findings – This work suggests a solution to overcome the difficulties and drawbacks associated with the notion “cooperative product” and to compare its similarities with a collective brand, which has been previously proposed as a brand development strategy for the Agricultural Cooperatives. Practical implications – The development of a Quality System especially designed for agricultural cooperatives’ products and, in combination with product certification, can be used as a part of their brand strategy. Originality/value – Agricultural cooperatives could build a brand development strategy based on quality systems, Total Quality Management elements and hence attain the benefits associated with their implementation.

Impacts of company size and culture on quality management practices in manufacturing organisations: An empirical study

Kit Fai Pun, Surujdaye Jaggernath-Furlonge — 2012-01-06 00:00:00.0

Abstract

Purpose – The purpose of this paper is to investigate the impacts of company sizes and culture on quality management practices (QMP) in manufacturing organisations based in Trinidad and Tobago (T&T). Design/methodology/approach – Empirical data were collected via a questionnaire survey, and 65 manufacturers in four different sizes were studied. The analysis of survey data was performed with the aid of SPSS. Findings – The study signified five core dimensions of culture that would facilitate QMP implementation, and their relative importance would be dependent on varying company size. Organisation size appears to affect only the culture dimension of Low Power Distance. Research limitations/implications – This research has its limitations due to the fact that the samples were selected manufacturers with varying sizes in T&T. Direct measurements of the impacts of varying company size on culture and QMP were not included in the study. Originality/value – The findings provided some insights in diagnosing the cultural dimensions and in developing quality culture in manufacturing organisations of T&T.