Implementation of Six Sigma using DMAIC methodology in sugar industry

Six Sigma is a methodology that focuses on process improvement. It has many tools that are within the Six Sigma DMAIC toolbox (Define, Analyze, Improve, and Control). These tools help breakdown a process, analyze it, and put controls in place to improve the process from that point forward. DMAIC is a nonstop cycle that will continually improve the process. This research was conducted by using two primary objectives as a guideline. The first objective of this research is to study the implementation of Six Sigma using DMAIC Methodology in manufacturing of sugar industry. Second objective of this research is to improve the monitoring techniques by analyzing the data using Capability Six pack on Carbonation tank at melting process. The process selected was from manufacturing of sugar which focusing on carbonation tank. The parameters involved at this tank were pH of diluted liquor, retention time and temperature during settling of lime and carbon dioxide adding in the tank. However, this study was monitored the pH condition only. The technique applied was DMAIC as a solution to reduce the most common defects encountered. The analysis from employing Six Sigma and DMAIC indicated that high color is the highest defect that influenced the amount of defective sugar produced. In particular, the six pack capability of variance techniques by using Minitab 17 Software was used to statistically determine the correlation. Then, it details the application of Six Sigma with DMAIC in the XYZ Company, which obtained an increasing sigma level from 2.98 to 3.87 after the process improvement.