IMPLEMENTATION OF SIX SIGMA AND QUALITY CONTROL TOOLS IN A FLY ASH BRICK MANUFACTURING PLANT

Abstract

This paper describes the implementation of Six Sigma and quality control tools in a Fly ash brick (FAB) manufacturing plant to meet the quality standards of bricks and customer satisfaction. Due to ever increasing demand of bricks in the construction industry from the infrastructure as well as the real estate sector, it has become necessary to have quality control on the manufacturing process. The critical objective of manufacturing industries nowadays is to deliver a product to the customers as per the required standards and specifications within a stipulated time and cost, minimization of waste and efficient use of resources. Six Sigma principles with an effective DMAIC methodology in construction industry emphasizes on reducing variations in processes and eliminating the root causes of defects. In this statistical analysis using excels software and cause-and-effect analysis using Minitab was done. The variables which were affecting the production quality of bricks were measured and suggestions for reducing the defect level were recommended by using DMAIC principles of six sigma. The results showed that with the proper application of this methodology, and support from the team and staff of the organization, a positive impact on the quality and other features critical to customer satisfaction can be achieved for the organization.