Bottleneck Identification And Process

Improvement By Six Sigma DMAIC

Methodology

GROUP MEMBERS :
M UH A M MA D A H SA A N SAD IQ (20 -I E-0 3)

MU H A MM A D H AS SA A N (2 0-I E -14 )
 o It was introduced by American engineer Bill Smith
 while working at Motorola in 1986.

o Six Sigma (6σ) is a set of techniques and tools for

process improvement.

What is six o It provides organizations tools to improve the

sigma 6σ ? capability of their business processes.

o “Six Sigma quality" is a term generally used to indicate

a process is well controlled.

oIt consists of five phases also called DMAIC.

 purpose:

o All industrial companies want to increase uptime, reduce operational costs, and boost productivity and throughput.
However, bottlenecks in manufacturing are one of the primary reasons why processes get delayed, budgets burst from the
added cost of delays and the whole process becomes unpredictable.

oIt is also a fact that bottleneck in manufacturing exists regardless of how well factory workers and machinery are
working.

o That is why it is important for manufacturers to know how to accurately identify the bottleneck in manufacturing in
production so that they can take the necessary measures to avoid the costliest ones whenever and wherever they occur.
 methodology:

o We analyzed a food processing company with major focus on the production and packaging departments that had
bottlenecks and high defect rate. Our major objective was to identify and eliminate the bottlenecks and to improve the
production processes by applying DMAIC method.

o Based on the analysis we have derived an action plan detailing the implementation of chosen solutions by modifying the
existing 5S system of the company.

o Suggestions were given to improve the overall equipment efficiency, to improve the productivity and to reduce the
production fluctuations through DMAIC and six sigma initiatives.
Problem statement:
 Case Study:
Customers arrive at an ATM of HBL branch Ghanta Ghar chowk Multan. According to a Poison process at the
rate of one customer per minutes and the service time is an exponential random variable 0.83 minutes. Find
(a) Average number of customers in the ATM
(b) The average number of customers in queue
(c) Average waiting time a customer spends in the queue

(d) The average time a customer spends in waiting for service

(e) Utilization rate
(f) Idle time
Solution:
  Hours

Week days 9-10 AM 10-11 AM 11-12 AM 12-1 AM Total Customers/week

Saturday 30 75 50 50 205

Sunday 130 40 35 40 245

Monday 60 50 20 35 165
Tuesday 20 10 30 40 100
Wednesday 38 93 56 85 272
Thursday 80 75 128 80 363

Friday 95 80 77 78 330

        Average 240
Solution:
(a) The average number of customers in the shop
Ls =

Ls =

  Ls = 5 customers
Solution:
(b) The average number of customers in queue

Lq = Ls -
= 5-
= 4.16 customers
Solution:
(c) The average waiting time a customer spends in the system

WS =

WS =

WS = 5 Minutes
Solution:
(d) The average time a customer spends for waiting in service
WQ =

WQ =

WQ =4.16 minutes
Solution:
(e) Utilization factor/rate of the ATM is :
Ꝭ=
 
Ꝭ=
(f) Idle time of the ATM is :
Ꝭ0=1- Ꝭ

Ꝭ0=1- 0.83

Ꝭ0=0.23
Tora Result: