Study On Application Of Six Sigma Management To HY Company

Six Sigma Management formed in MOTOROLA in 1980s, it has been adopted by worldwide companies and contributed remarkable achievements to them. Practice has proved that Six Sigma Management is a complete set of management idea and method, which can make the enterprise keep continuous improvement, enhance comprehensive leadership, improve customer’s satisfaction, improve business performance and acquire huge profits.HY Company was a manufacturing enterprise which produced speaker box, it had problems of low productivity and low qualified rate of products, HY decided to adopt Six Sigma Management method, to improve productivity and qualified rate of products, decrease production cost, and promote management level. In this thesis, two processes of improving productivity and qualified rate of paintwork were introduced.Six Sigma’s improving model DMAIC was used to increase productivity, DMAIC refers to Define, Measure, Analyze, Improve and Control. After cause and effect diagram analysis, it was concluded that process time was the main factor that led to low productivity. Observation was carried out to get operation time of each process, and their distribution fitting were analyzed in minitab. Then flexsim software was applied to build model and implement simulation, after confirming the bottleneck process, improvement was made to decrease its process time according to the principle of ECRS, which refers to Eliminate, Combine, Rearrange and Simple. After that, model was built and simulation was implemented in flexsim, simulation result was satisfactory. Desired result was achieved when improved operation method was taken into actual work.Then DMAIC was used to improve the qualified rate of paintwork. After analyzing the potential factors that caused low qualified rate, it was concluded that main factors were painting works’ operation method, temperature and humidity in painting shop. Based on further analysis of these two factors, it showed there were two reasons led to low qualified rate, one was that the worker who painted the secondary orange-peel varnish couldn’t keep airbrush vertical with the surface to be sprayed while painting, the other reason was that temperature and humidity were affected by outside. So the painting worker accepted training and did well according to specification. Then according to the two phases of response surface method, first steepest ascent was used to find optimal area of temperature and humidity, second the response surface experiment was implemented in the optimal area, and quadratic regression equation between qualified rate of paintwork with temperature and humidity was established according to experiment. It was calculated that the most appropriate temperature was 26.6 ℃, the most appropriate humidity was 55.0%RH, the corresponding qualified rate was calculated to be 98.28%.The results showed that after applying Six Sigma Management method, HY Company’s daily average output was increased from 101.3 pieces to 125.4 pieces, average qualified rate of paintwork was expected to increase from 90.93% to 98.28%. In the perspective of finance, because of the elimination of overtime work, production cost could be saved 147600.0 Yuan each year, and rework cost was expected to be reduced 47939.0 Yuan due to the improvement of qualified rate of paintwork. So application of Six Sigma Management to HY Company had achieved initial success.