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The purpose of this paper is to identify, study and quantify the effects of lighting on yield and productivity in manual electronics assembly (MEA) and inspection as a limiting work design criterion. The study also examines the potential interactions among lighting option, workers' age, and years of experience.

A three‐factor full factorial experiment is adopted to statistically evaluate the independent variables (process yield and assembly time) versus randomly selected levels of three factors: type of light (low pressure sodium, mercury vapor lamps, and metal halide lamps measured in foot‐candle luminaries), operator age, and years on the job. A residual analysis is also conducted to complement and corroborate the ANOVA findings.

The study finds that metal halide lamps, based on the ANSI recommended ranges of 186‐464 foot‐candles, lead to significant increases in labor productivity and through‐put, irrespective of operators' age and years of experience. Although these lamps have a significantly shorter life span than that of low‐pressure sodium and mercury vapor lamps, the realized benefits far exceed the incremental cost of illumination devices. The results indicate that a modest capital investment is able to generate solid improvements in yield and processing time in a typical MEA environment.

The relations between productivity and lighting intensity and type have never been studied in the area of MEA. This empirical study uncovers the effects through a systematic experimentation of this essential relationship in a typical MEA environment. The findings, which can be generalized to other facilities, are validated by an array of statistical procedures and proved to be significant. The paper contributes useful knowledge to the fields of engineering management and facility design.

The purpose of the study is to measure the current or baseline institutional performance level of the Government and private engineering colleges in the state of West Bengal.

The study has been conducted on the basis of a survey. The feedback for this survey questionnaire has been considered independently for service providers such as administrators, faculties, other supporting staff as well as students who receive these services and are direct customers. A total of 2,168 persons have been surveyed from the 30 randomly selected colleges out of 70 colleges. The baseline or current performance level of the engineering colleges has been assessed based on the sigma level through quantification of the survey questionnaire consisting of eight enablers. Each enabler contains several questions or drivers. A total of 75 drivers have been arrived at for eight enablers. A seven‐point scale has been designed for each driver ranging from “Unsatisfactory” to “Outstanding”. To identify the weak areas for a college, the vital few drivers that correspond to “Unsatisfactory” performance have been made to take necessary remedial measures for attaining the new benchmark sigma level under the present techno‐economic set‐up.

The overall ratings (sigma levels) of engineering colleges in West Bengal range from 0.11 to 2.7, which is far away from the sigma level (4σ) of an average organization in the USA.

The paper is a purely original work. Instead of going by the popular perception of the Selection, Engineering and Technology, West Bengal, it is much better to categorize the colleges based on the class intervals of baseline sigma levels as demonstrated.

Success and business reputation depend upon the quality of products where product quality depends upon the capability of a process, yield value and sigma score, etc. Poor quality of ceiling fan and mass rejection from quality check resulted in an alarming amount of cost for rework. As a result, the fulfillment of the production target was getting difficult day by day. The main purpose of this research is to identify the crucial causes for humming noise of ceiling fans and control it to a tolerable level so that maximum quality can be achieved.

The poor quality of ceiling fans was determined from the Pareto analysis of the define, measure, analyze, improve and control model which was humming noise during running and further actions were undertaken regarding the reduction of the humming noise. Project charter was formed before initiating the measure phase to study the suppliers, inputs, processes, outputs and customers diagram with process parameters and existing noise data were collected from random samples to determine the rolled throughput yield (94.95% existing) and existing sigma score which value of 3.14 and also the poor value (1.05) of process potential index implied that the process condition was below standard (<1.33) and need to be improved badly. Then root causes analysis and relationship diagram was prepared to identify the possible causes and with the design of experiments and correlation analysis, it was clear that the air gap between the stator and rotor was the main culprit behind the humming noise.

The minimum value of air gap was determined from boxplot analysis which was 0.2 mm–0.225 mm and the corresponding mean, the minimum and maximum value of sound level in dB (37.5–40.3 dB) for 0.225 mm air gap with the watt consumption (83 w) from the hypothesis test for the corresponding air gap. Finally, the updated sigma score and process capability analysis were performed with control charts to show the comparison after applying the DMAIC-six sigma methodology. The final sigma score was 5.1 which indicates a significant improvement of the process with the capability of saving US$23,438/year caused by the poor quality of ceiling fans.

Only quantitative values of the causes behind the humming noise were possible to identify. Other trivial many causes elimination might improve the sigma score closer to 6.00. The final sigma score that was achieved from this research was sustainable.

A structural approach with proper data analysis and application of various tools to detect the actual cause behind the humming noise of ceiling fans with numerical value has not been found in any literature. This research study can be a valuable asset for ceiling fan mass producers.

The technological development and characteristics of an innovative process and composition for immersion plating and fusing of a solderable tin/lead deposit over copper are discussed. The process offers a viable alternative to hot air solder levelling, electrodeposition/selective stripping, or inhibitor coatings for maintaining solderability of printed wiring boards. A flat, uniform solderable tin/lead coating on all feature surfaces and edges is achieved. A number of important benefits are derived. The ability to coat any copper surface uniformly, including fine pitch features, is substantially enhanced. Solderability is improved because of a thick, flat, co‐planar and uniform tin/lead deposit on all copper surfaces. Typical thickness and composition of the fused alloy are 150 to 300 microinches (4 to 8 microns) and 65 to 75% tin.

The purpose of this paper is to improve the yield of a particular model of a car windshield, as the organization faces losses due to poor performance and rejection.

The Six Sigma DMAIC (define, measure, analyze, improve and control) methodology is used to reduce variation and defects in the process. It is a methodology based on data-driven and fact-based analysis to find out the root cause of the problem with the help of statistical analysis. A worst performing model is selected as a case study through the scoping tree. The preprocess, printing, bending and layup process defects are reduced by analyzing the potential causes and hypothesis testing.

This paper describes Six Sigma methodology in a glass manufacturing industry in India for automotive applications. The overall yield of a car windshield achieved 93.57 percent against the historical yield of 88.4 percent, resulting in saving 50 lacs per annum. Due to no rework or repairing in the glass, low first-time yield causes major losses. Process improvement through focused cross-functional team reduces variation in the process. Six Sigma improves profitability and reduces defects in the automotive glass manufacturing process.

This case study is applied in automotive glass manufacturing industries. For service and healthcare industries, a similar type of study can be performed. Further research on the common type of processor industry would be valuable.

The case study can be used as a problem-solving methodology in manufacturing and service industries. The tools and techniques can be used in other manufacturing processes also. This paper is useful for industries, researchers and academics for understanding Six Sigma methodology and its practical implementation.

This case study is an attempt to solve automobile glass manufacturing problems through DMAIC approach. The paper is a real case study showing benefits of Six Sigma implementation in the manufacturing industry and saving an annual cost of 50 lacs due to rejections in the process.

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.

Six Sigma is a business strategy and a systematic methodology, use of which leads to breakthrough in profitability through quantum gains in product/service quality, customer satisfaction and productivity. The concept of implementing Six Sigma processes was pioneered at Motorola in the 1980s and the objective was to reduce the number of defects to as low as 3.4 parts per million opportunities. For the effective implementation of Six Sigma projects in organisations, one must understand the critical success factors that will make the application successful. This paper presents the key ingredients, which are essential for Six Sigma implementation. These ingredients are generated from a pilot survey conducted in the UK manufacturing and service organisations.

Six sigma for small‐ and medium‐sized enterprises (SMEs) is an emerging topic among many academics and six sigma practitioners over the last two to three years. Very few studies have been reported about the successful applications of six sigma in SMEs. The purpose of this paper is to provide an analysis of six sigma implementation in UK manufacturing SMEs.

This paper presents an extensive literature review based on the experiences of both academics and practitioners on six sigma within an SME environment. The paper highlights the strengths and weaknesses associated with SMEs, followed by the results of a six sigma survey in UK manufacturing SMEs. The results of the study are based primarily on descriptive statistics.

The results of the study show that many of the SMEs are not aware of six sigma and many do not have the resources to implement six sigma projects. It was also found that lean sigma was not generally popular among SMEs. Management involvement and participation, linking six sigma to customers and linking six sigma to business strategy are the most critical factors for the successful deployment of six sigma in SMEs.

This paper reports the first study on the status of six sigma implementation in UK SMEs. The paper will yield a great value to academics, consultants, researchers and practitioners of six sigma.

This paper reports the results of a pilot study on the implementation of Lean Six Sigma (LSS) in East African service and manufacturing organizations. The purpose of this paper is to determine the critical success factors for implementation of such a strategy as well as any barriers. A further aim was to determine the knowledge, usage and usefulness of LSS tools and techniques within those organizations.

A quantitative approach was taken utilizing a survey questionnaire which was sent to a sample of organization employees who had attended Yellow, Green or Black Belt LSS training courses organized by the Kenya Institute of Management in Nairobi. Employees attending such courses came from Kenya, Uganda, Tanzania and Rwanda.

Results indicate that the most useful tools are most of the original seven tools of quality improvement proposed by Ishikawa over 50 years ago and the most important factor for successful implementation of LSS is management involvement and participation.

The main limitation is that this is a pilot study so to confirm the findings a full survey of East African organization needs to be undertaken.

The findings have implications for trainers, consultants and practitioners with regards to the implementation of LSS within organizations as well as the focus of the content of LSS training courses.

This paper reports the first study on the implementation of LSS in East Africa and will be of value to practitioners, trainers, consultants and researchers of LSS in East Africa and beyond.

In recent times, the idea of taking advantage of the benefits of simulation techniques and Six Sigma discipline altogether has led various organizations towards implementation of simulation tools within Six Sigma methodology. The purpose of this study is to provide a more comprehensive literature review on the topic exploring how this amalgamation could work both in theory and practice. This precisely entailed finding dependable studies that shows how Six Sigma (DMAIC) Methodology can be enhanced by the three prevalent simulation techniques; Agent-Based (AB), Discrete-Events (DE), System Dynamics (SD).

A systematic literature review was considered more fitting in research because it involves rigorous and well-defined approach compared to other forms of literature review. In this case, the literature was comprehensive, well-encompassing and involved finding Six Sigma and Simulations literatures from reputable scholarly databases. The outcome of these reviews was the identification of a set of key finding compiled and classified by topics. The study follows an inductive approach and utilises a meta-synthesis review technique.

As numerous studies assert, simulation techniques including AB, DE and SD are applicable tools in almost every stage of DMAIC, especially the Analyse, Improve and Control phases, because of their capability to test and identify potential bottlenecks and improvement areas. Findings show that the simulation tools such as CLDs, Group Model Building, Dynamic Balance Scorecards and Cost of poor quality all have the potential to add value to a Six Sigma methodology.

The findings of this study highlight the importance of further inquiry in this area of study. The finding of this study suggests that although the study on the integration of Six Sigma and simulations is increasing, empirical evidence on its effectiveness is still limited. Therefore, this study suggests more roadmaps and investigations aimed at merging Six Sigma methodology and various simulation technique. Moreover, studies that centre on hybrid or multi-method simulations within Six Sigma are also urgently necessitated.