Developing Methodology for Process Capability Enhancement & Rework Reduction on an FMCG Processing Plant using DMAIC approach

Abstract

In the world of manufacturing focused process improvement and continuous excellence using six sigma (DMAIC) for an overall reduced manufacturing cost, reworking, process improvement and semi-filed losses have become the need of the time. This became an inspiration for developing a new methodology of process improvement using the tools and techniques of DMIAC. The industry selected for the development was the fast manufacturing consumer good (powder milk production) plant. The objective of the research was to reduce the rework, semi filled losses(material losses) and enhance the overall process capability of the production plant with a specific focus on documenting and developing the skills of the employees in on organized and structured way. The methodology devised followed the 5 step DMAIC framework with specific tailored changes to suit the specific needs of the project. The DMAIC methodology adopted with real production data analysis revealed 38.5% reduction in losses, 0.98% to 1.34% loss reduction per shift and decreased standard deviation from 1.48 to 0.78, while providing cost savings of up to PKR 13 million. The research also incorporated documented skill development program that proved to be an essential tool for skill enhancement and management. The process capability was greatly enhanced by the methodology resulting is a process sigma level enhancement from 1.65 to 2.56.