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The paper aims to identify the effect of ignorance of correlatedness among process observations and to implement new sampling schemes; skip and mixed sampling, in order to reduce the effect of autocorrelation on process capability index (PCI) Cpm.

Autocorrelated observations are generated using autoregressive process of order two (AR (2)) using Monte Carlo simulations. The PCI is computed based on these observations assuming the independence. The skip and mixed sampling schemes are then used to form sub-groups among correlated observations. The PCI obtained using sub-groups from skip and mixed sampling schemes are assessed using sample mean and sample standard deviation.

The paper provides empirical insights into how the effect of autocorrelation decreases in the estimated value of PCI Cpm. The use of new sampling schemes, skip and mixed sampling, reduces the effect of autocorrelation on estimates of PCI Cpm.

This paper fulfills an identified need to study how to reduce the effect of autocorrelation on PCI Cpm.

Continued quest for business improvement in terms of enhanced productivity and cost cuts is the most valued strategic function in an organization. Towards this endeavor, there have been evolutions of many problem-solving techniques like Lean, quality control (QC) tools, Six Sigma, total productive maintenance (TPM), etc. This paper introduces a different problem-solving methodology for quality improvement – prepare, measure, define, establish, control and stabilize (PMDECS) approach of Red Bin Analysis (RBA) – and presents empirical evidence of its effectiveness in eliminating the defectives at source (parts per million [PPM]) and improving the process capability (Cp).

An attempt has been made to compare RBA with the Six Sigma methodology in terms of number of defects, defectives, process capabilities, project duration, etc. Data validation with more than 2000 data points was conducted based on empirical data collected over multiple problem-solving projects conducted in six manufacturing industries of India to compare the effectiveness of both the methods. Finally, fuzzy AHP (analytical hierarchy process) model was proposed to identify the Quality Improvement Index for both the methods to address the manager’s dilemma in selecting an appropriate problem-solving method.

The paper provides empirical insights in establishing that the PMDECS approach of RBA is at par and sometimes better for problem-solving if the problem is not chronic and is at the initial stages, it requires less duration than Six Sigma projects and except casting process and it can yield better results in case of PPM rejection or Cp/Cpk improvement in other processes.

Because of the chosen research approach, the research results may lack generalizability. This research has been specifically conducted in automotive manufacturing industries. Therefore, researchers are encouraged to test the proposed propositions further.

The paper includes implications for the usage of alternative problem-solving methods, like PMDECS approach of RBA.

This paper intends to compare how the results of six sigma projects in manufacturing industries are effective against a different methodology, PMDECS approach of RBA.

The present paper proposes a framework for zero-defect manufacturing in Indian industries. Due to the current competitive market, there is a strong need to achieve zero defects from the customer's perspective. A survey questionnaire is analyzed based on the responses and a structured framework is drafted to implement zero defect manufacturing in the Indian industry.

To analyze zero-defect in Indian industries, a literature review and a survey questionnaire constituted a framework. This framework is independent of the type of process and product.

The findings of this study are based on a total of 925 responses received through survey questionnaires by different mediums. The framework has been tested in different manufacturing organizations to achieve zero-defect through the continuous improvement approach.

The study results aim to achieve zero-defect, help to improve customer satisfaction, reduce waste and rework in the manufacturing process. This framework is also used as a problem-solving approach to implement Six Sigma in the Indian industries.

Zero defect manufacturing is growing in India and globally. This framework helps to implement zero defect manufacturing in Indian industries. It is an essential tool to capture the voice of the customer.

To ensure product quality within a manufacturing process, inspection processes are indispensable. One task of inspection planning is the selection of inspection characteristics. For optimization of costs and benefits, key characteristics can be defined by which the product quality can be checked with sufficient accuracy. The manual selection of key characteristics requires substantial planning effort and becomes uneconomic if many product variants prevail. This paper, therefore, aims to show a method for the efficient determination of key characteristics.

The authors present a novel Algorithm for the Selection of Key Characteristics (ASKC) based on an auto-encoder and a risk analysis. Given historical measurement data and tolerances, the algorithm clusters characteristics with redundant information and selects key characteristics based on a risk assessment. The authors compare ASKC with the algorithm Principal Feature Analysis (PFA) using artificial and historical measurement data.

The authors find that ASKC delivers superior results than PFA. Findings show that the algorithms enable the cost-efficient selection of key characteristics while maintaining the informative value of the inspection concerning the quality.

This paper fills an identified gap for simplified inspection planning with the method for the efficient selection of key features via ASKC.

This paper aims to unearth the essential components of Six Sigma for successful deployment and sustainment of service quality in four different organizations in the United Arab Emirates (UAE). More specifically, the paper is intended to determine the motivation to apply Six Sigma, Voice of Customer, Key Performance Indicators (KPIs), Critical-to-Quality (CTQ), readiness factors, Critical Success Factors, sustainment measures, tools and techniques used, challenges/barriers and performance impact on the company.

An exploratory research methodology with multiple case study analyses was adopted to determine the answers to the research objectives. Four case studies from different service processes of four companies were analyzed. The case studies were collated from these companies via a case study protocol with pre-defined criteria.

The analysis shows that service operation improvement projects are primarily dependent on the voice of the internal customer, with return on investment in savings as the KPI of the process. Most organizations prefer cycle time and errors as the CTQs in the Six Sigma projects. Even novice users can effectively apply the Six Sigma methodology with external experts’ assistance, mentoring and interventions. Across the case studies, it is observed that the projects were successfully deployed due to the support of top management leadership, effective communication and cross-functional teams. Employee resistance to change is the common barrier observed during the case study analysis. Eventually, in all the four case studies, Six Sigma is executed with standard tools and techniques within the define, measure, analyze, improve, control (DMAIC) approach.

The present study’s findings cannot be generalized due to the limited number of case study analyses in different ecosystems in the UAE. The authors would like to analyse and report more case studies in service quality improvement through the Six Sigma methodology to comprehend and develop a generic roadmap for the deployment of Six Sigma in the UAE service industry.

The study’s findings provide insights into commonalities and differences between the essential factors of Six Sigma deployment and sustainability in UAE companies.

The study results might help the policymakers and key decision makers in UAE and other countries understand the effectiveness of Six Sigma in service quality improvement with its essential factors for deployment.

Logistics sector is recognized as one of the core enablers of the economic development of a nation. However, inefficiency in logistics operations impedes the achievement of intended targets by increasing the cost of doing business. Also, it is difficult to improve the efficiency of a country’s logistics operations without a metric for evaluating and understanding logistics capabilities and efficiency. Therefore, the present study has developed In-country Logistics Performance Index (ILP Index) to propose a benchmarking tool to measure the in-country logistics competitiveness, particularly in the setting of emerging economies, i.e. India.

This study has developed a unified index using principal component analysis and quintile approach. In addition, the proposed index relies on several dimensions that are developed and illustrated using quantitative secondary panel data.

The findings of this study reveal that the quality of infrastructure, economy, and telecommunications are the three most important dimensions that may significantly support the growth of the transportation and logistics sector. The results reveal that Gujarat, Tamil Nadu, and Maharashtra are the top performers whereas, Bihar, Jharkhand, and Jammu and Kashmir scores the least due to the insufficient logistics infrastructure as compared to other Indian states.

Given the extensive focus on international-level logistics index (like World Bank’s LPI) in the existing literature, this study intends to develop in-country logistics index to evaluate the logistics capabilities at the regional and state level. In addition, unlike prior studies, this study utilizes quantitative secondary data to eliminate cognitive and opinion bias. Moreover, this benchmarking tool would assist decision-makers in idealizing standard practices toward sustainable logistics operations. Additionally, the ILP index could serve the international investors in crucial decision-making, as it provides valuable insights into a country’s logistics readiness, influencing their investment choices and trade preferences. Finally, the proposed approach is adaptable to measuring the overall performance of any other industry/economy.

This chapter of the book aims to introduce multiobjective linear programming (MLP) as an optimum tool to find the best quality engineering techniques (QET) in the main domains of supply chain management (SCM). The importance of finding the best quality techniques in SCM elements in the shortest possible time and at the least cost allows all organizations to increase the power of experts’ analysis in supply chain network (SCN) data under cost-effective conditions. In other words, this chapter aims to introduce an operations research model by presenting MLP for obtaining the best QET in the main domains of SCM. MLP is one of the most determinative tools in this chapter that can provide a competitive advantage. Under goal and system constraints, the most challenging task for decision-makers (DMs) is to decide which components to fund and at what levels. The definition of a comprehensive target value among the required goals and determining system constraints is the strength of this chapter. Therefore, this chapter can guide the readers to extract the best statistical and non-statistical techniques with the application of an operations research model through MLP in supply chain elements and shows a new innovation of the effective application of operations research approach in this field. The analytic hierarchy process (AHP) is a supplemental tool in this chapter to facilitate the relevant decision-making process.

Industry 4.0-driven digitalisation is said to offer a way to redesign traditional compliance-oriented quality management (QM) models. However, despite a rising academic and practitioner interest, it is still unclear how companies transform their current QM models to meet the real-time needs of the new manufacturing paradigm. The purpose of this study is to explore practices for the digitalisation of QM and to uncover the digitalisation journey.

An exploratory research approach of an embedded case study of a multinational auto-component manufacturer was adopted to achieve the research aim.

A guiding framework called the “Quality 4.0 transition framework” was developed based on literature and expert knowledge. The framework is made up of three building blocks, i.e. the foundation of “as-is” digitalisation maturity assessment; pillars representing horizontally and vertically integrated QM processes, and roof signifying reinforcement of total quality management (TQM) principles at all levels.

The study provides empirical evidence of the case company's digitalisation journey to avert product recall due to field failure issues. The study contributes to theory and practice in many ways. First, the study uses empirical data from a real-world case to understand how digitalisation affects QM processes. Next, the guiding framework for the Quality 4.0 transition adds to the existing literature on the digitalisation of business processes.

This study aims to utilise Six Sigma in an Irish-based red meat processor to reduce process variability and improve yields.

This is a case study within an Irish meat processor where the structured Define, Measure, Analyse, Improve and Control (DMAIC) methodology was utilised along with statistical analysis to highlight areas of the meat boning process to improve.

The project led to using Six Sigma to identify and measure areas of process variation. This resulted in eliminating over-trimming of meat cuts, improving process capabilities, increasing revenue and reducing meat wastage. In addition, key performance indicators and control charts, meat-cutting templates and smart cutting lasers were implemented.

The study is one of Irish meat processors' first Six Sigma applications. The wider food and meat processing industries can leverage the learnings to understand, measure and minimise variation to enhance revenue.

Organisations can use this study to understand the benefits of adopting Six Sigma, particularly in the food industry and how measuring process variation can affect quality.

This is the first practical case study on Six sigma deployment in an Irish meat processor, and the study can be used to benchmark how Six Sigma tools can aid in understanding variation, thus benefiting key performance metrics.

This study investigates the repetitive mixed sampling (MRS) plan based on the Cpk index that was proposed by Aslam et al. (2013a). They were the first to study the MRS plan, but they did not pay attention to the fact that submitting to the variable inspection a sample that was first submitted to the attribute inspection, truncates the X observations. In addition, they did not work with an accurate expression to calculate the probabilities of the Cpk statistic.

The authors presented the results based on their original sampling plan through Monte Carlo simulation and defined the theoretical results of their plan when the sample submitted to the variable inspection is no longer the same one submitted to the attribute inspection.

The β risks of the optimum sampling plans presented by Aslam et al. (2013a) are pretty high, exceeding 46%, on average – this same problem was also observed in Saminathan and Mahalingam (2018), Balamurali (2020) and Balamurali et al. (2020), where the β risks of their proposed sampling plans are yet higher.

In terms of originality, the authors can declare the following. It is not a big deal to propose new sampling plans, if one does not know how to obtain their properties. The miscalculations of the sampling plans risks are dangerous; imagine the situation where the acceptance of bad lots exceeds 50% just because the sampling plan was incorrectly designed. Yes, it is a big deal to warn that this type of problem is arising in a growing number of papers. The authors of this study are the pioneers to discover that many studies focusing on the sampling plans need to be urgently revised.