Abstract:
Rejection rate of a product plays a very important role for customer satisfaction and financial conditions of any company. Rejection rate causes a direct effect on profit margin of a product and decreases the quality of a product. Therefore the companies are struggling to reduce their rejection rate during the process of manufacturing through different quality tools, checking and inspection during different operations and implementing changes and strict quality checks where more defects are produced. High rejection rate of polypropylene bags is the major problem faced by SYNTRON Ltd industry. This project is very important from industry point of view because high rejection rate is creating customer dissatisfaction and financial loss to organization. Reduction in rejection rate is the project in which it is successfully attempted to prompt-out root causes along with a number of factors by adopting Six Sigma methodology. It was decided to implement DMAIC methodology in extrusion and weaving departments where high rejection rate of PP bags was recorded. This research presents a comprehensive study which focuses on the implementation of six sigma. The main aim of this study is to introduce DMAIC process of six sigma. The problem was identified practically in polypropylene bags manufacturing industry in research. It was then measured to identify the extent of the problem so that it can be eliminated or reduced. Potential causes of problem was identified in the analyze phase. Finally, problem was improved by conducting Design of experiments (DOE) study and further strategy was made in control phase so that it can be controlled and monitored regularly to ensure that it was properly implemented and providing the desired results. The statistical work for the project was done in latest statistical software MINITAB 15.After that an optimum solution was suggested along with the areas of improvement which reduced rejection rate and provided a significant financial benefit.
