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Proceedings of 12th International Conference on Business Management

http://ssrn.com/link/12th-ICBM-2015.html
7th and 8th December 2015 | Colombo, Sri Lanka

A Case Study on Application of DMAIC to Improve Delivery
Efficiency
Tennakoon B.M.M.M
Palawatta T.M.B.
Department of Decision Sciences,
University of Sri Jayewardenepura

Abstract
Purpose – In this era of globalization, as competition intensifies, providing on timely
delivered products and services has become a competitive advantage and a need to ensure
survival. The Six Sigma’s problem solving methodology DMAIC has been one of the several
techniques used by organizations to improve the deliveries of their products and services.
This paper is based on an application of Six Sigma and DMAIC to improve on time deliveries
within a MDF boards manufacturing organization in Sri Lanka.
Design/methodology/approach – The paper follows the DMAIC methodology to
systematically investigate the root causes of delivery failures and provide a solution to
improve them. It begins with the past data analysis of the problem to find out major causes
for delivery failures and after finding major causes further analysis is done to find out sub
critical causes. Then reasons are analyzed for these sub causes and for these analyses Pareto
charts, Brainstorming, Fish bone diagrams and verification sheets are used as tools and
techniques. Finally to find out key root causes 5Y analysis is used and solutions have been
proposed to overcome these issues.
Findings – Product quality issues and Plant availability issues were the most problematic
cause for delivery failures. Further analysis noted, Shives, Crack marks and Rough surface
were the most problematic quality defects and to loss plant availability several mechanical
and production related plant down time issues were caused. Metering belt broken, Doffing
rolls drive chain broken and fibers leaking from gland packing at refiner 01 were the most
significant causes identified as mechanical related plant down times and out feed board
blockage, refiner 01 blow line blockage and forming line scalper exhaust line blockage were
the most significant production related plant down time causes.

1
Faculty of Management Studies and Commerce
University of Sri Jayewardenepura
Gangodawilla, Nugegoda
E-Mail: icbm@sjp.ac.lk
WEB: www.icbmusjp.org, mgt.sjp.ac.lk

Electronic copy available at: http://ssrn.com/abstract=2706992

Proceedings of 12th International Conference on Business Management
http://ssrn.com/link/12th-ICBM-2015.html
7th and 8th December 2015 | Colombo, Sri Lanka

Practical implications – This paper can be used as a guiding reference for managers and
engineers to undertake specific product and process improvement projects, in their
organizations, similar to the one presented in this paper.
Originality/value – This study presents an industrial case which demonstrates how the
application of Six Sigma and DMAIC can help manufacturing organizations to achieve
product quality and plant availability improvements in their companies and thus contribute to
their search for improvement of on time deliveries.

Keywords : Six Sigma, DMAIC, Defects reduction, Down time reduction, Manufacturing
process, MDF boards

Paper type - Case study

JEL Classification: D02

Introduction
To meet the customer requirements successfully it is necessary to deliver the products and
services on time and it is the secret behind the success of any business. Time is one of the key
factors customers are worried about. The businesses that do not consider time throughout
manufacturing and order taking process has a remote chance of success. Throughout the
entire process of supply chain management, consistent on time delivery is vital and in fact
very important for the success of any business.
ABC is a manufacturer of MDF (Medium Density Fiber) boards mainly for the export
market and brings us around 2.5million USD foreign currency into the country annually.
They are performing their manufacturing process using two major production lines along
with four value addition lines. The skilled production team at the high technology factory
converts raw materials in to a MDF sheet within few minutes and production is continuing
around the clock. ABC is monopoly in the island and has overseas competition from
Malaysia Robin MDF, Indian Bajaj MDF, china MDF etc. ABC customer base is handled
mainly by 32 agents operating from India, Pakistan, Middle East and Sri Lanka. According to
the sales reports of last six months in 2014, it has received 45352 m3 production orders and

2
Faculty of Management Studies and Commerce
University of Sri Jayewardenepura
Gangodawilla, Nugegoda
E-Mail: icbm@sjp.ac.lk
WEB: www.icbmusjp.org, mgt.sjp.ac.lk

Electronic copy available at: http://ssrn.com/abstract=2706992

lk Electronic copy available at: http://ssrn.ac.lk WEB: www. According to Harry and Schroeder (2000). 2004). in the Six Sigma’s terminology. retention and supplies the best in class products from the best in class process performance.org.com/abstract=2706992 . 2004).6% and that create lot of financial as well as non-financial losses. productivity and quality. Six Sigma is a powerful breakthrough business improvement strategy that enables companies to use simple and powerful statistical methods for achieving and sustaining operational excellence. Six Sigma can be defined as a team based approach to solving and process improvement. Six Sigma was proposed by Motorola company in the mid 1980s. Also according to Breyfogle et al. But according to Harry (1998) and Dasgupta (2003).It was an approach to enhance production. On time delivery failures can occur due to three major reasons.sjp. Sigma (σ) has been traditionally used to measure the variation in a process or its output (Omachonu and Ross. Six Sigma is a process focused program and aims to improve the process through systematic methodology. Also it increases the customer satisfaction. minimizing the variations and improving capabilities in the manufacturing process. Mainly it is a quality improving process of final product by reducing the defects. Particularly. According to Nabhani and Shokri (2009). One of them is plant quality related problems and the second is plant availability issues such as break downs of the machines and third is problems related to supply chain such as lack of raw materials and shipping issues. The Sigma’s name originates from the Greek alphabet and in quality control terms. Nugegoda E-Mail: icbm@sjp. to have a process which only produces 3.icbmusjp. According to Pyzdek and Keller (2012). mgt.ac. improve the financial condition through minimizing the defective rate of products. Six Sigma has been 3 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. Proceedings of 12th International Conference on Business Management http://ssrn.4 defects per million opportunities (DPMO). According to Bhote (1991). or in other words. But according to Pyzdek and Keller (2010).4 defects per every one million products produced (Stamatis.html 7th and 8th December 2015 | Colombo. a Six Sigma level refers to 3. (2001).com/link/12th-ICBM-2015. That means company success rate of on time deliveries is 61. Literature Review on six sigma and DMAIC Six Sigma The Six Sigma is a financial improvement strategy for an organization and nowadays it is being used in many industries. Sri Lanka the company has on time delivered only 27929 m3. as well as reducing operational costs. objective of Six Sigma is to increase the profit margin. the “Sigma level” is denoted as a company’s performance.

there are many considerations as presented below to achieve the financial goals of the organization.html 7th and 8th December 2015 | Colombo. the process improvement projects are carried out following well known define-measure-analyze-improve-control (DMAIC) or define-measure-analyze-design-verify (DMADV) disciplines. Voice of Customer (VOC) and Quality Function deployment (QFD). and feedback of customers and determine the product standard that we provide and quality service. DMAIC The DMAIC is a basic component of Six Sigma methodology and it is a better way to improve work processes by eliminating the defect rate in the final product (Pyzdek and Keller.ac. • Define phase According to Pyzdek and Keller (2012).com/link/12th-ICBM-2015.lk . According to Pyzdek and Keller (2012). Many organizations all over the world have derived significant financial benefits from effective deployment of these disciplines.lk WEB: www. Sri Lanka recognized as a systematic and structured methodology that attempts to improve process capability through focusing on customer needs. There are different tools which are used in defining phase like SIPOC. while the DMADV is used for designing a new process or product.sjp. in order to use Six Sigma in an organization.icbmusjp. After implementation of different improvement activities. Measure. The DMAIC methodology has five phases such as Define. Proceedings of 12th International Conference on Business Management http://ssrn. 2012). Find out what are the occurring defects and why these are occurred during the manufacturing process and how to reduce these problems by using different methods. scope and process background for both internal and external customers. consumer survey report. Further they explain the discipline of DMAIC used to improve an existing process or product. Nugegoda E-Mail: icbm@sjp. Improve and Control. Understand the needs and who your customers are.ac. and what product that you want to provide for the customers Review of the data. mgt.org. According to Harry and Schroeder (2000) article of Six Sigma. from this phase define the purpose of project. set up good matrices and follow up activities and become the new standard operating process. 4 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. Analysis.

This principle also known as the 80/20 (eighty twenty) rule and also it is used in the field of materials management in the form of ABC analysis. Pareto Diagram is a tool that arranges items in the order of the degree of their input. and then from that it is identifying a few items exerting maximum influence. mgt.ac. 2012).lk WEB: www. Nugegoda E-Mail: icbm@sjp.ac.lk .org.html 7th and 8th December 2015 | Colombo. Pareto diagram According to Magar and Shinde (2014). • Analyze phase According to Pyzdek and Keller (2012). Further he noted that such distribution pattern was regular in most fields. process flowcharts. this has been named to memorize Kaoru Ishikawa. Further Juran explains. • Prioritizing projects for quality improvement • Prioritizing setting up of corrective action teams to solve problems • Identifying the type of products on which most complaints are received • Identifying the type and gravity of complaints most often occurring • Identifying most recurrent causes for rejections or any other similar purposes. Proceedings of 12th International Conference on Business Management http://ssrn. Sri Lanka • Measure phase In order to determine the root cause of defects. Also analyze phase deploys a number of tools for collecting team input and conducting objective experiments to identify or confirm top causes.icbmusjp. process capability measurement and Gage R&R (Pyzdek and Keller. In the SPC this tool is used and its applications as follows.com/link/12th-ICBM-2015. Some of the important tools in this phase include trend charts. fishbone diagram is a tool for identifying the root causes of quality related problems. Pareto charts. who was a Japanese quality control statistician and the man who pioneered to use 5 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. Cause and Effect Analysis According to Juran (1999). this phase identifies the root causes of problems and confirms them from data analysis. focusing the data gather from current process for improvement.sjp. Further they explain as the origin of the tool lies in the observation by an Italian economist Vilfredo Pareto and he observed that a large portion of wealth was consumed by a few people.

ac. this is an analysis tool which provides an orderly way of looking at effects and the relevant causes that create or contribute for the effects. According to Ilie and. The structure provided by the diagram helps team members think in a very systematic way. Fishbone diagram may be named as a cause and effect diagram due to its function. have you ever stopped and asked “why” five times? If you do not ask the right question. mgt. you will not get the right answer.icbmusjp. fishbone diagram mainly represents a model of suggestive presentation for the correlations between an event or effect and its multiple happening causes.sjp. • Improve phase According to Pyzdek and Keller (2012). it should be started to solve at the end result.html 7th and 8th December 2015 | Colombo.lk WEB: www. “when confronted with a problem. • It is useful to determine the root causes for a particular problem or quality characteristic using a prearranged approach • It encourages group involvement to find relevant causes for a problem and utilizes group knowledge of the process • It identifies the areas where data should be collected for further studies Five Why Analysis As expressed by Serrat (2009) from his article ‘the five whys techniques’. Nugegoda E-Mail: icbm@sjp.lk . Because when question the answer five times it reflect on what really caused for that. the technique can only be a shell of the process. The main output is the 6 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla.org. The Five Whys is a simple question asking technique that explores the cause and effect relationships underlying problems”.com/link/12th-ICBM-2015.ac. some of the benefits of constructing a Fishbone diagram are. and from that can be adapted quickly and applied to a large amount of problems. Proceedings of 12th International Conference on Business Management http://ssrn. in this phase develop the solution of problems in the process by implementing the different tools like FMEA and pilot plan. Further as expressed by the Serrat (2009). This elementary and often effective approach to problem solving promotes deep thinking through continuous questioning. Most obviously and directly. the Five Whys technique relates to the principle of systematic problem solving without the intent of the principle. But according to Watson (2004). Further they explains. when looking to solve a particular problem. Ciocoiu (2010). Sri Lanka this chart in the 1960's.

Six Sigma implementation at exporting industries According to Kwak and Anbari (2006) there are five most important factors for six sigma implementation projects. evolution of the solution of problems and future plan and also maintains the standing operating procedure. But as per the Ismyrlis and Moschidis (2013).lk . management and control skills.html 7th and 8th December 2015 | Colombo.icbmusjp. training. statistical tools and techniques and data analysis. A list of critical factors available from various literature review done were listed by Ismyrlis and Moschidis (2013) and then were compared with the case industries in order to conclude the most prominent factors among exporting units. linking the Six Sigma project with business objectives and training on Six Sigma are the critical factors. Table 1: Critical success factors for Six Sigma implementation in case industries Critical Success Factors A B C D E F G H Top Management commitment √ √ √ √ √ √ √ √ Training and Education √ √ √ √ √ √ √ 7 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. continuous education and training and encouraging and accepting cultural change are those important factors.org. But according to Tjahjono et al. Further they explain as these factors are necessary for the successful implementation of Six Sigma. importance to financial benefits. Sri Lanka identification of planned actions that are implemented for improvement and should reduce the impact and also proposed solution to the problems.com/link/12th-ICBM-2015. • Control phase According to Pyzdek and Keller (2012). cultural change.ac. the most critical factor for implementation of Six Sigma is management commitment. Proceedings of 12th International Conference on Business Management http://ssrn. Management involvement and organizational commitment. As mentioned by Julien and holmshaw (2012).lk WEB: www. (2010). Top management commitment. clear and successful communication was also identified as important to successful implementation.5 gives outputs that among the 9 factors considered all the factors are equally important for successful implementation of Six Sigma. mgt. Focusing on such factor will make the implementation of Six Sigma a better success.ac. by using the data. The critical success factors in each of the case industries are studied and noted.sjp. linking it to business strategy. Table 2. project selection. committed leadership of top management and fully fledged training are crucial to success of Six Sigma implementation. Nugegoda E-Mail: icbm@sjp.

The most manufacturing industries in Asian region are using this technology and getting benefits by absorbing benefits to company’s bottom line through reducing process defects (Ismyrlis and Moschidis. 2006. Koh et al. As per the Nabhani and Shokri (2009).ac.icbmusjp. Proceedings of 12th International Conference on Business Management http://ssrn. have better customer services and have reductions in costs and inventory turns. well planned and executed SCM will enable organizations to reduce their inventories. mgt.lk . SC has become an important dimension for firms to give maximum attention in order to excel in a competitive environment. all firms within a SC must reduce functional silos and adopt a process approach.lk WEB: www. 1998. Competition is no longer between firms but between entire SCs. 8 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. So.com/link/12th-ICBM-2015. highly competitive environment supply chain (SC) performance is very vital for the survival of firms because customers judge the performance of firms based on their SC performance. According to Chong and Ooi (2008). Li et al.. The short term objective of SCM is to enhance productivity and reduce inventory and lead time whereas.html 7th and 8th December 2015 | Colombo. 2013). Six Sigma is a process focused program and aims to improve the process through systematic methodology and SCM also focused on processes within SC.org. Also in order to successfully implement SCM.sjp. 2007).. Sri Lanka Project selection √ √ √ √ Proper team formation √ √ √ √ √ Customer satisfaction and √ √ √ √ requirement Employee satisfaction √ √ Linking Six Sigma with Business √ √ √ √ √ √ √ Objectives Time based approach √ √ √ √ √ √ √ √ Proper documentation √ √ √ √ √ Above review shows the usage of DMAIC methodologies and the benefits of implementation in manufacturing industry. Application of Six Sigma for Supply Chain Management According to Mentzer (2001).ac. Further he explained as SCM has become a key strategic factor or tool for firms to improve their performance and secure their competitiveness in a market place. the long term objective is to increase companies’ market share and have external integration of the SC process (Tan et al. Nugegoda E-Mail: icbm@sjp. It has been argued that it is a good idea to use Six Sigma in SC projects in order to improve SC metrics..

mgt. Antony et al.(2005 has used DMAIC methodology to integrate human aspects and process aspects within the Six Sigma implementation. Proceedings of 12th International Conference on Business Management http://ssrn. supplier deliveries.html 7th and 8th December 2015 | Colombo. (2004) has investigated) how quality management can be employed in SCM to improve the performance of various issues in the whole SC network using Six Sigma methodology. Pareto graph was drawn and for this last six month period causes analysis were done. Importance of introducing the concept of Six Sigma DMAIC as an effective methodology for monitoring and controlling SC variables has been stated by Amer et al. quantity and quality. Nugegoda E-Mail: icbm@sjp. Further to solve these issues. According to that analysis Product quality issues (B) and Plant availability issues (A) were identified as the most significant on time delivery failure causes. Sri Lanka Trent (2001) has explained that original equipment manufacturers are spreading Six Sigma through the SC by offering training to suppliers.ac. on time delivery failures has occurred 152 times and when further analysis is done six main causes could be identified. Six Sigma DMAIC methodologies are used. 2014) past data analysis.sjp.icbmusjp. Also Nabhani and Shokri (2009) have presented the reduction of delivery lead time in food distribution with the implementation of DMAIC procedures based on the Six Sigma methodology. Six Sigma and DMAIC application – Case study: MDF manufacturing process Problem Analysis According to last six months of period (from July to December.lk . Also Wang et al.lk WEB: www. They are. people and equipment inconsistencies which need to be controlled or worked upon. in 2008.ac.com/link/12th-ICBM-2015. A – Plant availability issues B – Product quality issues C – Product mix issues D – Production planning issues E – Packing material issues F – Transportation issues To identify most significant causes for the on time delivery failures. Further Pullim (2002) believes SC performance is diminished because of different variation causes. such as demand fluctuations. 9 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla.org.

Measure Phase Selected six months period past data were analyzed to identify the exact quality related issues for on time delivery failures. Analysis Phase To identify all possible causes for the above selected quality defects.ac. Due to some quality problems if they can’t achieve customer requirements at that time there is no chance to produce shortfall due to above intermediate curing process and tight production schedules. Proceedings of 12th International Conference on Business Management http://ssrn.ac.html 7th and 8th December 2015 | Colombo.lk WEB: www. several brainstorming sessions were conducted. final quality inspections are done and all productions are kept in a separate location for at least 24 hrs before sanding for the curing process. a cause and effect diagrams (or fish bone diagrams or Ishikawa diagrams) were 10 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. mgt.org. Sri Lanka Application of Six Sigma DMAIC for product quality issues Define Phase According to ABC quality management system all boards’ final inspection is done by quality checkers and if found any quality related issue those boards are downgraded or segregated for re-grading. After collecting selected six months period factory quality related defects.com/link/12th-ICBM-2015. According to this Shives. Then in order to illustrate and categorized the possible causes of the problem. After boards sanding. to identify most significant defects Pareto analysis was done. Nugegoda E-Mail: icbm@sjp. 80% of quality related problems can be solved. According to our findings by addressing above mentioned main 3 defects.icbmusjp. Crack marks and Rough surface were identified as most problematic quality defects.sjp.lk .

To construct these diagrams four categories such as man. material and method (4M) were used. verification sheet was used and sample of it is shown below.icbmusjp.com/link/12th-ICBM-2015. Sri Lanka constructed. According to this. Does the cause Verification Analysis Cause Results contribute to the method method failure Less knowledge Data Operator Operator’s skill level is and skill of the analysis performance not satisfactory YES operators evaluation sheet Operator Observation Production and Very rare and there is NO negligence quality reports no problem 11 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla.org. machine.ac. Shives defect analysis Lack of employee training Poor machine Low hydraulic Man Machine Poor machine maintenance pressure Filter maintenance Less knowledge Oil Wear & tear of blockag and skill of the leakages Poor refiner machine e operators Use of low Machine unusual recruitme quality spares vibration nt Grinding plate Operator damage Poor grinding negligence Lack of Not proper plate alignment Improper work motivatio magnet Poor Poor magnetic schedule n cleaning attention strength Shives defect Shaker machine strainers damaged Loader operator Chip size Loader operator negligence deviation from the negligence standard Improper log Poor log No standardized mixing mixing method for refiner Poor Poor machine operating communication communicatio Material Method n The possible root causes for the Shives defect were illustrated in the cause and effect diagram.lk . To verify which causes were really contributed to the failure among above 9 causes.lk WEB: www.sjp. Proceedings of 12th International Conference on Business Management http://ssrn.ac. Nugegoda E-Mail: icbm@sjp. possible 9 main causes and 19 sub causes were identified under above four categories.html 7th and 8th December 2015 | Colombo. mgt.

Accordingly the reason for less knowledge and lower skill of the operators is that company do not have a proper employee recruitment policy and to overcome problem it is suggested to prepare proper employee recruitment policy including requirement of each job category and qualification of the new employees.ac. • Less knowledge and skill of the operators • Grinding plates damage • Improper log mixing To find out solutions for these causes 5Y (Five why) analysis is used. • Conveyor speed differences • Poor fiber quality According to 5Y analysis cause for conveyor speed differences is poor cleaning underneath the belts and reason for this is Day by day cleaning employees are changing and plant requirements are not properly communicating to them. Nugegoda E-Mail: icbm@sjp. To overcome this problem in future it is suggested to add magnet cleaning work for refiner assistant shift cleaning schedule. Proceedings of 12th International Conference on Business Management http://ssrn. Reason for improper log mixing is that there is no standardized method for log yard operations. To overcome this problem it is suggested to prepare standardized method. Also according to 5Y analysis reason for grinding plate damage is improper magnet cleaning and hence magnetic strength reduced. which can be practically applied for log yard operations. According to verification sheet we can conclude 2 main causes that mainly contributed to the Crack mark defect are. Then all causes were illustrated in the cause and effect diagram. mgt. To overcome this problem it is suggested to appoint contract supervisor for their operations handling.sjp.icbmusjp.org.com/link/12th-ICBM-2015.ac.html 7th and 8th December 2015 | Colombo. including 12 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla.lk . Crack mark defect analysis From the brainstorming session 9 possible main causes and 15 sub causes could be identified. Sri Lanka According to verification sheet we can conclude 3 causes are mainly contributed for the Shives defect and those are.lk WEB: www.

13 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. Proceedings of 12th International Conference on Business Management http://ssrn. mgt.html 7th and 8th December 2015 | Colombo. Also technical solutions can be given by implementing conveyor belts motion loss alarms as indicators for belt slipping.lk WEB: www. Therefore it is suggested to insulate whole dryer to maintain consistent temperature and on the other hand it prevents heat loss of the dryer and it will be of great advantage to the company in terms of energy conservation. Sri Lanka Lack of employee training Man Poor cleaning works Machine Conveyor drive Less knowledge and malfunction Conveyor belt slipping skill of the operators Poor Conveyor speed recruitment Belts elongation differences Operator Poor loader functioning negligence Lack of Improper work motivation Poor PLC malfunction schedule attention Crack mark Less operator attention defect No way to check Sudden boiler pressure individual fiber Poor PM planning dropping quality Poor fiber quality No place to take fiber sample No proper method for Fiber moisture Sudden boiler pressure fluctuating conveyor speed dropping checking Sudden environmental Material temp changes Method training casual employees and communicating plant requirements to them properly.icbmusjp.org.com/link/12th-ICBM-2015.ac.ac. According to 5Y analysis reason for poor fiber quality is the environmental temperature variation and this can’t be controlled.lk . Nugegoda E-Mail: icbm@sjp.sjp.

Sri Lanka Rough surface defect analysis Lack of employee Accidently press stops or training Man metal parts pressing Machine Sander Machine Less knowledge and unbalances Press plate skill of the operators Wrong balancing Poor unbalance Improper Sander machine recruitment Simultaneous arm jack calibration problems Operator problems Thickness Adjustment negligence Lack of Poor mat column fault Fiber Mat scraping Improper work motivation forming Poor Fiber transport line schedule attention Air controlling fault blockage Rough surface Refiner operator poor defect Improper wood logs Poor production attention Suction cleaning is not mixing Sudden boiler pressure planning enough dropping Inappropriate mat Poor fiber pre pressing quality Conveyor belts Fiber moisture slipping Sudden boiler pressure fluctuating dropping Material Method From the brainstorming session 11 possible main causes and 19 sub causes could be identified.org. To overcome this problem it is suggested to introduce reward program for the fitters after 14 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. verification sheet was used. Proceedings of 12th International Conference on Business Management http://ssrn.ac. Also according to 5Y analysis cause for fiber mats scraping is poor gap plate aligning work by fitters and reason for this is too much works and poor motivation of fitters. To overcome this problem it is suggested to give main priority for press calibration work during shut down period because this is a multi steps job and needed more time and therefore after employees are tired with maintenance work it will not give expected quality of work. • Press plate unbalance • Fiber mats scraping • Poor fiber quality • Conveyor belts slipping Above poor fiber quality and conveyor belts slipping also caused for the crack mark defect and solutions has been given and therefore other two causes were addressed.lk .html 7th and 8th December 2015 | Colombo. Nugegoda E-Mail: icbm@sjp.lk WEB: www. Then all causes were illustrated in the cause and effect diagram and to verify which causes were really contributed to the failure among above 11 main causes.icbmusjp. Cause for press plate unbalance is poor shut down planning and setting least priority for this job.com/link/12th-ICBM-2015. mgt.ac. According to verification sheet we can conclude 4 main causes mainly contributed to the rough surface defect and those are.sjp.

Proceedings of 12th International Conference on Business Management http://ssrn. mgt.lk .sjp.ac.icbmusjp.org.ac.com/link/12th-ICBM-2015.html 7th and 8th December 2015 | Colombo.lk WEB: www. Nugegoda E-Mail: icbm@sjp. Sri Lanka 15 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla.

lk .ac.html 7th and 8th December 2015 | Colombo.com/link/12th-ICBM-2015. Nugegoda E-Mail: icbm@sjp. Proceedings of 12th International Conference on Business Management http://ssrn.sjp.ac.icbmusjp.org.lk WEB: www. mgt. Sri Lanka 16 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla.

mgt.html 7th and 8th December 2015 | Colombo. • PM checkers fault • Wear & tear of chain links According to 5Y analysis. solution is proposed from above step and by successfully completing that solution this problem can be eliminated.ac. verification sheet was used.lk . Nugegoda E-Mail: icbm@sjp.lk WEB: www. But continuing inspection is needed till replacement of whole chain by removing defective chain links. Proceedings of 12th International Conference on Business Management http://ssrn.ac. Then all causes were illustrated in the cause and effect diagram and to verify which causes were really contributed to the Metering belt broken issue. 17 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. Reason for heavy fiber emission is fiber bin air pressurizing due to cyclone separators rotary valve air controlling flaps breaking. Sri Lanka Mechanical related plant down time analysis Metering belt broken Lack of employee Poor machine Man Machine training maintenance Poor strength materials Less knowledge and skill Wear & tear of chain of the fitters Poor links Poor Use of low quality Wear & tear of drive cleanings recruitment spares railings PM checkers C-Channels broken Lack of and blocked Misalignment of guide Improper work motivation sprocket Poor attention Poor strength materials Broken or loosen of schedule tightening bolts Metering Poor Oiling and Belt Broken greasing Overfilling Poor strength C.icbmusjp. To avoid fiber emission from the bin.org.sjp. To overcome this problem it is suggested to repair cyclone separators of all rotary valves air controlling flaps as soon as possible. due to heavy fiber emission from the fiber bin barrier the PM checking of metering belt fault occurs. According to verification sheet we can conclude 2 main causes have mainly contributed for the metering belt broken down times and those are. among above 14 main causes. Also due to above reason lubrication retaining on the chain is poor and always lubrication removing with contaminated fiber on the chain.com/link/12th-ICBM-2015. Metering belt drive path Focusing short term fiber bin Channels using changing (creating more benefits sag) Poor quality Always wetting chain Fiber fallen on the chain chain links due to top cyclone & railings Due to fiber washing Less knowledge of Material Method emissions from ordering cyclones From the brainstorming session 14 possible main causes and 13 sub causes could be identified.

org.html 7th and 8th December 2015 | Colombo. Suggest to add a guiding spocket in between drive motor and top doffing roller. mgt. Proceedings of 12th International Conference on Business Management http://ssrn. Then all causes were illustrated in the cause and effect diagram 18 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla.ac. Above analysis as a solution for crack marks has been proposed the way to reduce moisture content of fiber and this will also help to reduce chain broken issues. among above 12 main causes. According to verification sheet we can conclude 2 main causes are mainly contributed to the Doffing rolls drive chain broken down times and those are. its long distance traveling without any guiding spocket need to be corrected.lk . Nugegoda E-Mail: icbm@sjp.sjp. • Long distance chain travelling without any guiding spocket • Too much resin dozing & high moisture Lack of employee Man Poor machine Machine maintenance Poor modification training works Less knowledge and Wear & tear of chain skill of the fitters Poor links & spockets Use of low Long distance chain Poor cleanings travelling without recruitment quality spares PM checkers Misalignment of any guiding spocket Too much fiber negligence Lack of drive spockets filling in the fiber Improper work motivation Poor Spocket tighten Wrong alignment bin due to wrong schedule attention key loosen Doffing rolls Improper drive chain Operator un instructions Broken avoidance Overfillin Too much resin Focusing short Poor Oiling g fiber bin dozing & high term benefits and moisture Always wetting Poor quality chain due to top chain using Due to fiber cyclone washing Less knowledge Material Method emissions from of ordering cyclones To avoid doffing rolls drive chain broken. Then all causes were illustrated in the cause and effect diagram and to verify which causes were really contributed to the Doffing rolls drive chain broken issue.com/link/12th-ICBM-2015. HMR amount of resin dozing need to be readjusted. Also special products such as Shutter.icbmusjp. verification sheet was used. Sri Lanka Doffing rolls drive chain broken As the above issue brainstorming session was conducted and from that 12 possible main causes and 15 sub causes could be identified.lk WEB: www.ac. Fibers leaking from gland packing at refiner 01 Brainstorming session was conducted and from that 12 possible main causes and 21 sub causes could be identified. Also whole chain and spocket sets changing from single chain (1R) to double chain (2R) is another consistent solution for this problem.

Rotor is a disk rotating around 1500 rpm and it’s balancing is confirmed by manufacturer. If this is unbalanced heavy vibration can be occurred. 19 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. Proceedings of 12th International Conference on Business Management http://ssrn.icbmusjp. Grinding plates has two sets named rotor and stator. wear and tear of machine parts are high due to poor refiner machine maintenance works. mgt. Nugegoda E-Mail: icbm@sjp. Rotor also can be unbalanced due to its plate damaging while running from metal parts.lk WEB: www. Poor shut down planning is the main cause for such poor maintenance works. Rotor vibration also caused for the fiber leaking from gland packing’s.com/link/12th-ICBM-2015.ac. Sri Lanka and to verify which causes were really contributed to the Refiner 01 gland packing fiber leaking issue. among above 12 main causes. This cause was addressed from Shives defect analysis and solution has been given to overcome this reason. To avoid such a down time issue proper maintenance work is essential and for that proper planning is important.org.sjp.lk .ac.html 7th and 8th December 2015 | Colombo. According to verification sheet we can conclude 2 main causes are mainly contributed to the Refiner 01 gland packing fiber leaking and those are. Therefore suggest to conduct a pre maintenance meeting before shutdown works planned and according to that job lists and human resources need to be planned. verification sheet was used. • Wear and tear of machine parts • Rotor vibration Lack of Man Poor machine Machine Machine parts M/C operating employee maintenance wear&Low tarehydraulic violating training Less knowledge Wear & tare of oil pressure instructions Oil filter blockage and skill of the machine parts Use of low quality Poor Refiner Rotor vibration fitters spares recruitment operator’s Refiner segment PM Misalignment of rotor negligence Poor damage Low flow of seal steam checkers Lack of plate with stator attention and seal water Improper work motivation Poor M/C parts wear out Wrong alignment Line blockage schedule Fiber leaking from attention from fiber gland packing at Focusing more Focusing short refiner 01 fiber output Over pressurizing term benefits refiner M/C Low quality Low flow Column PRV malfunction Poor quality machine spares of pack gland Focusing short Not following operating Less term benefits procedures knowledge of (cost) Pressurizing from top ordering Material Method managers for quick start up According to 5Y analysis.

icbmusjp. According to verification sheet we can conclude 2 main causes are mainly contributed to the out feed board blockage down times and those are. • Lug chain slipping • Boards spread out from the press Lack of employee Poor machine Man Machine Less knowledge Boards aligning Lug chain jack malfunction and skill of the Star cooler wrong Poor Use of low quality spares Star cooler bars Soft pressing Poor cleaning wrong positioning due to Press Boards spread out Lack of PLC malfunction Improper work Board length from the press motivation Poor Poor press calibration increasing Conveyor belt Out feed board blockage High moisture Boards crack Using poor Refiner operator Boards blown sharpening saws Press operator from the press negligence from the press Poor fiber quality negligence Boards spread out Poor adjustment Boards double of out feed with due to fine fiber Poor feeding to star Boiler pressure Material Method dropping 20 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla.lk WEB: www.html 7th and 8th December 2015 | Colombo.com/link/12th-ICBM-2015. Then all causes were illustrated in the cause and effect diagram and to verify which causes were really contributed to the out feed board blockage issue. Proceedings of 12th International Conference on Business Management http://ssrn. But fiber recycling is also cause for the several quality issues later and therefore such boards blockages need to be stopped. Also if oil pressure below the required value alarm need to be displayed on refiner operators screen and then filter cleaning work need to be done. From the brainstorming session 14 possible main causes and 16 sub causes could be identified.lk . Out feed board blockage This is very critical issue because if this happens production line needs to be stopped or continue fiber recycling is essential. As a solution for this problem oil filter cleaning need be done at each refiner main motor stoppage time and this should be done by shift fitter. refiner 01 blow line blockage and forming line scalper exhaust line blockage.ac. mgt. among above 14 main causes. verification sheet was used.sjp.ac. Nugegoda E-Mail: icbm@sjp. Sri Lanka Also due to hydraulic oil filter blockage refiner machine vibration can be occurred and then rotor vibration can be initiated.org. Production related plant down time analysis Three significant causes could be identified for production related plant down times and those are out feed board blockage.

To overcome this problem suggests to prepare preventive maintenance schedule for hydraulic drive pump for every 3 months period. Then all causes were illustrated in the cause and effect diagram and to verify which causes were really contributed to the blow line blockage issue. mgt. among above 9 main causes. According to verification sheet we can conclude main cause is over dozing resin content from refiner 01 resin pumps. Proceedings of 12th International Conference on Business Management http://ssrn. Sri Lanka Lug chain slipping from its spockets is the one of major reason for out feed board blockage. Therefore recommended to replace lug chains and needed spockets immediately and those should be added to weekly PM check list. hydraulic drive pump pressure malfunctioning is the cause for boards spread out from the press and not having proper preventive maintenance planning is the reason for drive pump failures.ac. Lack of employee Operator training Man Machine negligence Less knowledge Over dozing and skill of the Poor resin content refiner operators Blow valve recruitment PLC malfunctions malfunction Avoiding operating Operating air line Charley valve instructions Lack of failure Improper work malfunction motivation Poor Diverting jack schedule attention failure Refiner 01 blow line blockage Poor quality raw material No special cleaning tools for emergency blockage Poor attention of the Poor quality relevant people resin No spare line for the Resin No standardized method for emergency use preparing fault blow line cleaning Poor Material Method contingency planning 21 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. Also lug chain tensioning is important to avoid such a down time.html 7th and 8th December 2015 | Colombo. Refiner 01 blow line blockage From the brainstorming session 9 possible main causes and 13 sub causes could be identified.ac. According to 5Y analysis. Also non availability of spare line is caused for the increase plant down times.lk . Nugegoda E-Mail: icbm@sjp.sjp.lk WEB: www.org. verification sheet was used. Reason for slipping is spockets and chain wear out and those has not replaced for a long period of time.icbmusjp.com/link/12th-ICBM-2015.

among above 12 main causes. Also by doing frequent blow line cleaning from stoppages is supported for continuing without blocking.icbmusjp. By doing this if blockage happened within short period of time refiner machine can be started. Sri Lanka Most of times line blockage could be seen from special products such as Shutter.ac. Proceedings of 12th International Conference on Business Management http://ssrn. Forming line scalper exhaust line blockage From the brainstorming session 12 possible main causes and 12 sub causes could be identified.html 7th and 8th December 2015 | Colombo.lk .sjp.org.com/link/12th-ICBM-2015. mgt. Therefore optimal level of resin needed to get required properties should be identified and to be fixed. According to verification sheet we can conclude main causes for the issue are that there are no planned methods for exhaust line cleaning and improper plant start up’s after fire incidents. Then all causes were illustrated in the cause and effect diagram and to verify which causes were really contributed to the blow line blockage issue. Preparing additional line is another good alternative solution to reduce plant stoppage down times.lk WEB: www. Lack of Man Elevator motor Machine employee failure training Less knowledge Forming belt and skill of the Scalper slipping Poor Poor drive failure press operators Exhaust blower recruitment attention Drive belts failure Lack of broken Avoiding Drive belts broken operating motivatio Improper n metering belt instructions Improper work speed up PLC schedule Forming line Communication failure scalper exhaust line blockage Poor mat Air Starting forming method controlling productions without issue Poor operator skill duct drying No planned Poor Improper plant method for quality start up after exhaust line fiber Poor fire High cleaning contingency moisture Material Method planning 22 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. Nugegoda E-Mail: icbm@sjp. HMR and reason for these are higher dozing resin to get high performance and excess resin coated around blow lines. verification sheet was used.ac.

icbmusjp. Then Pareto graph was drawn to identify most significant causes for the on time delivery failures and it clearly shows that product quality issues and plant availability issues were the most problematic cause for delivery failures. That means their successive on time delivery rate was 61. grinding plates damage and improper log mixing were the main three causes contributed for the Shives defect.6% and it create lot of financial as well as non-financial losses. Above mentioned six months period ABC had short shipped 152 containers and therefore they had to pay additional 24365 USD as cost for returned container charges and shipping penalty charges. But all these ducts are closed circuit and therefore it takes much more time to evaporate water and dry inside water of duct lines. Another reason for exhaust line blockages are improper plant start up’s after fire incidents.ac. mgt. Proceedings of 12th International Conference on Business Management http://ssrn. This is another major reason for line blockages. Sri Lanka First cause is there is no standardized. To overcome this problem it is proposed to prepare proper start up schedule after fire incident. who clean it and what frequency clean it.com/link/12th-ICBM-2015. poor knowledge and skill of the operators.lk WEB: www. To find out causes for delivery failure past data was analyzed and subjected six main causes could be identified. 23 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla.html 7th and 8th December 2015 | Colombo. According to further analysis. According to analysis at present they clean exhaust lines after down time was reported and till that they don’t worry about its condition. pre-defined method for exhaust line cleanings. it has received 45352 m3 production orders and from that they have on time delivered only 27929 m3. But most of the times company management worries about production output and don’t allow to dry wetted duct lines after such incident. Discussion According to ABC sales reports for selected six months (from July to December 2014) period. 5Y analysis were used to find out real root causes for these problems and according to analysis.sjp. Then again fiber is deposited around wetted duct lines and its transporting volume is reduced. As per the selected six month period past data analysis Shives.lk . Also top management must be highly committed to follow procedures and given instructions to ground level operations.ac. After fire generating on mat forming line to stop it’s spreading out and ceased it water is used.org. To eliminate such down times need to be prepared cleaning schedule for all duct lines including scalper exhaust line. It should clearly indicate how clean it. Nugegoda E-Mail: icbm@sjp. Crack marks and Rough surface were the most problematic quality related defects need to be addressed.

Four main causes could be identified for the rough surface defects and those were press plate unbalance. Also fiber mats scraping has happened due to poor aligning of gap plates between conveyor belts and reason for this is too much works and poor motivation of fitters.icbmusjp. suggest to prepare standardized method which can be practically applied for log yard operations. Nugegoda E-Mail: icbm@sjp. Therefore it is suggested to insulate whole dryers to maintain consistent temperature and on other hand it prevents heat losses of the dryers and it will be great advantage to the company. Reason for poor cleaning is the shifting employees day by day and plant requirements are not properly communicated to them. Poor fiber quality and conveyor belts slipping were addressed from above defect and reason for press plate unbalance was poor planning and giving least priority for press calibration work. Also poor magnet cleaning and therefore its magnetic strength reducing was the main root cause for grinding plate damages and to overcome this problem in future it is suggested to add magnet cleaning work for refiner assistant shift cleaning schedule.html 7th and 8th December 2015 | Colombo. fiber mats scraping. Also technical solution can be given by implementing conveyor belts motion loss alarms as indicators for belt slipping. Also to overcome improper log mixing issue.lk .ac. Also suggested to monitor their workload and balance it by recruiting new fitters if needed.lk WEB: www. Environment temperature variation was the key cause for poor fiber quality and this was out of our control.org. other than wood logs separation. poor fiber quality and conveyor belts slipping. To overcome this problem we suggested to initiate reward program for the fitters after inspecting quality of their work.com/link/12th-ICBM-2015.sjp. To avoid this problem it is suggested to appoint a contract supervisor for operational handling. mgt. training casual employees and communicating plant requirements properly. Proceedings of 12th International Conference on Business Management http://ssrn.ac. When preparing this. As a solution for this problem it is suggested to suggest to prepare proper employee recruitment policy including requirement of each job category and qualification of the new employees. Also transfer of inspection responsibilities to press assistant and then communicate that to contract supervisors is another solution we can apply. FIFO needs to be considered Also conveyor speed differences and poor fiber quality were the main two causes for crack mark defects and conveyor belts slipping due to poor cleaning is caused for conveyor speed differences. Sri Lanka company poor employee recruitment policy was the main effect for less knowledge and skill of the operators. 24 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. To overcome this high priority need to be given for press calibration work and maintenance work planner need to be educated to plan calibration work early in the shutdown planning works.

long distance chain travelling without any guiding spocket and too much resin dozing & high moisture were the two main causes contributed for Doffing rolls drive chain broken down times.icbmusjp. As per in detail analysis Metering belt broken. Sri Lanka According to selected six month period plant down time analysis.ac. This cause has been addressed from shives defect analysis and solution has been given to overcome this problem. the reason for PM checkers fault could be found and that was the PM checking difficulty due to fiber emission from fiber bin as a result of air pressurizing. Nugegoda E-Mail: icbm@sjp. Doffing rolls drive chain broken and fibers leaking from gland packing at refiner 01 were the most significant causes for mechanical related plant down times and out feed board blockage. mgt. mechanical related and production related plant down time issues were the most problematic causes for loss of plant availability. Also two main causes could be identified for the refiner 01 fiber leaking from gland packing issue and those were wore and tear of machine parts and rotor vibration. To overcome next issue suggest to readjust the amount of resin dozing for special products. But continued inspection is needed till renew whole chain by removing defective chain links. refiner 01 blow line blockage and scalper exhaust line blockage were the most significant causes for production related plant down times. As per the analysis.html 7th and 8th December 2015 | Colombo.lk .org.sjp.com/link/12th-ICBM-2015. Also whole chain and spocket sets changing from single chain (1R) to double chain (2R) is another consistent solution for this problem. Heavy fiber emissions from the fiber bin were the reason for wear and tear of chain links and successfully implementing above proposal this issue can be eliminated. As per the analysis two main causes were mainly contributed for the metering belt broken down times and those were PM checkers fault and wear and tear of chain links. When further analysis was done . Rotor also can be unbalanced due to its plate damaging while running from metal parts. To overcome this problem it was suggested repairing all cyclone separators rotary valve air controlling flaps as soon as possible. Poor shutdown planning works were the main reason for wear and tear of machine parts and to improve proper maintenance and planning works.ac.lk WEB: www. suggest to conduct a pre maintenance meeting before shutdown works planned and according to that job lists and human resources need to be planned. When further analysis was done real root cause could was found and that was cyclone separators rotary valve air controlling flaps broken. Proceedings of 12th International Conference on Business Management http://ssrn. Also due to hydraulic oil filter blockage refiner 25 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. To overcome first issue suggest to add a guiding spocket in between drive motor and top doffing roller. Then fiber emission from bin will be reduced and it will also support to keep our environment cleanly.

Proceedings of 12th International Conference on Business Management http://ssrn. Over dozing resin content from refiner 01 resin pumps and non-availability of spare line were the reason for blow line blockage issue. who clean it and what is the frequency to clean it.org.com/link/12th-ICBM-2015. resin dozing controlling is essential and preparing additional line is important to reduce plant down times. Also lug chain tensioning is important to avoid such a down time.ac. 26 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. Also to succeed this.lk WEB: www. Out feed board blockage. It should clearly indicate how to clean it. due to weak preventive maintenance planning was the reason for boards spread out from the press and to overcome such issue it is suggested to prepare preventive maintenance schedule for hydraulic drive pump for every 3 months period. To eliminate second down time cause propose to prepare proper start up schedule after fire incident.html 7th and 8th December 2015 | Colombo. top management high commitment to follow procedures and given instructions to ground level operations are essential. Therefore recommended to replace lug chains and needed spockets immediately and those should be added to weekly PM check list.lk . refiner 01 blow line blockage and forming line scalper exhaust line blockage were the three significant causes could be identified for production related plant down times. mgt. no standardized. cleaning schedule need to be prepared for all duct lines including scalper exhaust line. Nugegoda E-Mail: icbm@sjp. According to analysis. Sri Lanka machine vibration can be occurred and then rotor vibration can be initiated. Reason for lug chain slipping is spockets and chain wear out and those has not replaced for a long period of time. To overcome this blow line related down times. To eliminate first down time cause.ac. As a solution for this problem suggest to clean oil filter at each refiner main motor stoppage time. Poor hydraulic drive pump calibration work.icbmusjp. Because most of the times company management worries about production output and don’t allow to dry wetted duct lines after such fire incident. Lug chain slipping and board spread out from the press were the two main causes could be identified for out feed board blockage issue. By successfully implementing these proposed actions company can improve their quality level as well as plant availability level and finally it will support to improve on time deliveries for delighting their customers. pre-defined method for exhaust line cleaning and improper plant start up’s after fire incidents were the major two causes for scalper exhaust line blockages.sjp.

lk . No. 27 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. Kumar. Breyfogle. Further it saves around USD 48730 annually. 2. ‘An application of Six Sigma methodology to reduce the engine overheating problem in an automotive company’. mgt. M & Tiiwari.ac. SH & Ashraf. pp. 355-366. Vol. AYL & Ooi. T 2003. 4. B 2001. Total Quality Management & Business Excellence. Vol. World-class quality: using design of experiments to make it happen. Cupello. 3. ‘Using the six sigma metric to measure and improve the performance of a supply chain’. Wiley. but due to limited time frame this study will not highlight the improvement of plant efficiencies. ‘Adoption of inter-organizational system standards in supply chains: an empirical analysis of Rosetta net standards’. JM & Meadows. Bhote. By achieving all these objectives the plant efficiency will be increased. No. Sri Lanka Conclusions and Recommendations With above analysis we can conclude. 219. pp. New York. ‘Optimizing order fulfillment using design for Six Sigma and fuzzy logic’.icbmusjp. Therefore further studies can be done to identify the root causes for these implementation barriers that exist and to formulate proactive approaches. Managing Six Sigma. Vol. NY.sjp. American Management Association. MK 2005. Industrial Management and Data Systems. 3.org. No. New York.com/link/12th-ICBM-2015. With the successful implementation of proposed solutions the industry can improve the manufacturing performances and hence on time deliveries by improving quality and plant availability. International Journal of Management Science and Engineering Management. 108. 83-99. Antony. The findings of this study shows that with the application of six sigma performance of any company can be improved and six sigma is a powerful to along with other tools used in the study. 8. 2nd edn. MA 2008. Vol. pp. Lee. Nugegoda E-Mail: icbm@sjp. Journal of Engineering Manufacturer. FW. Y. pp.html 7th and 8th December 2015 | Colombo. Chong.lk WEB: www. Proceedings of the Institution of Mechanical Engineers. References Amer. this study provides a practical application of six sigma techniques in MDF board manufacturing. KR & Bhote. AK 1991. 14. 633-646. J. Luong. KB 2008. With reduction of process defects and plant down times it leads to improve the customer expectations with on time deliveries. L. Dasgupta. No. This study was carried out to improve on time deliveries by using Six Sigma DMAIC in MDF board manufacturing company in Sri Lanka.ac. 529-547. Proceedings of 12th International Conference on Business Management http://ssrn.

31. ‘Supply Chain Management’. 3. A 2009. P 2012. pp. P 2012. JE 2004. ‘Six Sigma in a low volume and complex environment’.F & Shokri. 3.ac.lk WEB: www. Magar. Ragu-Nathan. International Journal of Management Science. 103-124. pp. RB 1998.org. SS 2006. Vol. Six Sigma fundamentals: a complete guide to the system. ‘Six Sigma’s critical success factors and tool box’. Demirbag. pp. Serrat. Sri Lanka Harry. No. 20. ‘The five whys techniques’.sjp. London. NY. Juran. O 2009. ‘The impact of supply chain management practices on performance of SMEs’. Omega. J 2002. Koh. V & Moschidis. Productivity Press. Vol. Vol. New York. No.. 107-124. methods and tools.html 7th and 8th December 2015 | Colombo. Professional Engineering. black belts. 708-715. Washington. 1-20. 32. Ragu-Nathan. Vol. Bayraktar. M. 7. MJ 1998. 2. International Publications. 3rd edn. No. VB 2014. The Handbook for Quality Management. Sage Publication. pp. Ismyrlis. Vol. SC. PA 2010. 1-8.com/link/12th-ICBM-2015. McGraw Hill. No. 26. pp. Florida. Industrial Management & Data Systems. mgt.lk . Omachonu. Li. KC. T & Keller. No. Nugegoda E-Mail: icbm@sjp. Doubleday. Pullim. p. R 2000. International Journal of Lean Six Sigma. FT 2006. VR & Handfield. 108-117. 8. 28-44. Vol. Tatoglu. 2. 2-9. Vol. Quality Progress. Vol. A Complete Guide to Operational Excellence Pyzdek. Journal of Manufacturing Technology Management. 34. pp. S 2007. YH & Anbari. Ilie. 1. E & Zaim. obstacles and future of six sigma approach’. B. Principles of total quality. 5th Edn. ‘Supply chain management: supplier performance and firm performance’. MJ & Schroeder.2nd edn. 1. The Six Sigma handbook: a complete guide for green belts. Mentzer. 15. ‘The impact of supply chain management practices on competitive advantage and organizational performance’. 4. Issue 1. pp. Harry. Tan. Six Sigma: The Breakthrough Management Strategy Revolutionizing the World’s Top Corporations. Vol. TJ 2001. Tec novation. McGraw-Hill Companies Inc. pp. No. Vol. CRC Press LLC.957 – 974. Stamatis. Nabhani. E. and managers at all levels. 4. no. JM 1999. D & Holmshaw. No. ‘Reducing the delivery lead time in a food distribution SME through the implementation of six sigma methodology’. VM & Shinde. ‘Success comes in threes’. ‘Application of 7 Quality Control Tools for Continuous Improvement of Manufacturing Processes’ International Journal of engineering Research and General Science. ‘Benefits. O 2013. Pyzdek. 3rd edn. 2. New York. S. New York. 28 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. DH 2004. TS & Rao. 28. T & Keller. Julien. Kannan. CN 2010.icbmusjp. 5. ‘Juran's Quality Handbook’. Vol. pp. 107. ‘Six sigma: a breakthrough strategy for profitability’. No.ac. pp. 2. Management research and practice.G & Ciocoiu. ‘Application of fishbone diagram to determine the risk of an event with multiple causes’. Kwak. International Journal of Lean Six Sigma. Proceedings of 12th International Conference on Business Management http://ssrn. International Journal of Purchasing and Materials Management. VK & Ross. 60- 64.

Sri Lanka Tjahjono.com/link/12th-ICBM-2015.sjp. C. ‘Six Sigma: a literature review’. Vol. Vitanov. Nogueira. ‘The Legacy of Ishikawa’. ‘Product driven supply chain selection using integrated multi criteria decision making methodology’. A. mgt. pp. P. S & Yadav. VI. 37(4). A. Wang. No. 1. JP 2004. G 2004. L. B.lk . M. No.icbmusjp. J. 70-78. ‘Applying TQM to SCM’.lk WEB: www.ac.html 7th and 8th December 2015 | Colombo. Vol. G. 5. Supply Chain Management Review. Narasimha. Dismukes. No. Srivastava. Watson. Scorzafave. *********************************************************** 29 Faculty of Management Studies and Commerce University of Sri Jayewardenepura Gangodawilla. Quality Progress. Trent. RJ 2001. Vol. H. 91. 3. 1-15.ac. Nugegoda E-Mail: icbm@sjp. Y 2010. Proceedings of 12th International Conference on Business Management http://ssrn. Huang Samuel. pp. 3. pp. 1. 54-47. Rivas. No. Minguet. J. International Journal of Production Economics.org. pp. 216-233. Srivastava. International Journal of Lean Six Sigma. Calleja. Ball.