Six-Sigma Quality for Fuel Manufacturing

Abstract

It is widely recognized that operational performance in product manufacturing is largely determined by understanding and maintaining process capability. By definition, Six Sigma is a statistical unit of measure reflecting process capability that yields less than 6.8 defects per million product produced. Statistically, this translates into obtaining a long term manufacturing process capability of +/- 4.5 standard deviations about the mean within specification limits.

The heart of the Six Sigma program developed by the Six Sigma Academy is what we refer to as the Breakthrough Strategy. This rigorous analytical methodology is the driving force in obtaining world class performance of Six Sigma. The methodology applies statistical and practical tools in resolving a problem or improving a product or process.

The application of Six Sigma focuses on attacking process input variables (independent) rather than the output variables. Focusing on these independent variables (temperature, power, force, etc.) and the variation in the end product they create, enables us to get to the root of the problem rather than react to the symptoms of the problem. In this manner we prevent defects from occurring rather than inspecting and monitoring the product.

Why the need for such an ambitious program? It is estimated that the cost of failure (rework, scrap, warranties, etc.) can be as high as 15% of sales for companies typically operating at 3-4 sigma. In achieving Six Sigma, costs of failure are typically less than 5%. The thought of reducing business costs while achieving the recognition of being our customer's premier choice provides enormous incentive to reach such status.