Reducing failure rate at high voltage (HV) testing of insulator using Six Sigma methodology

Purpose: This paper, a case study, aims to illustrate the application of Six Sigma in a small-scale ceramic manufacturing industry. The purpose of this paper is to demonstrate the empirical application of DMAIC methodology to reduce failure rate at high voltage (HV) testing of one of the most critical products, insulator. Design/methodology/approach: The case study is based on primary data collected from a real-life situation prevailing in the industry. The case study methodology adopted here is at one small-scale unit wherein the authors have applied DMAIC methodology and observed and recorded the improvement results, especially, reduction in failure rate at HV testing of insulator and, thus, increase in Sigma level. Findings: The results found after implementation of the solutions are very significant. The rejection percentage has been reduced from 0.5 to 0.1 percent and consequently the Sigma level has been improved from 4.4 to 5.0. Research limitations/implications: This success story can be a guiding roadmap for other such industries to successfully implement Six Sigma to improve quality, productivity and profitability. Practical implications: This case study will serve as one of the resource bases for the industries which have till not implemented Six Sigma and benefited from the same. Social implications: Improved quality and productivity leads to better economy. This case will help industries to serve the society with better economy with improved quality and productivity. Originality/value: Though ceramic industries in India are having enormous potential for growth, majority of them, especially, small and medium industries are either not aware of or not implementing Six Sigma to reap its multidimensional benefits of improving quality, productivity and profitability. This study highlights the benefits reaped by small-scale ceramic manufacturing industry opening up the avenues for its application at other such organizations.