Six Sigma in Metal Industry

The metal industry is considered by many as one of the most complex industries since it involves the proper handling of heavy materials to guarantee that the results of their manufacturing and production are high in quality and are error-free. If you are part of the metal industry, then note that you can actually seek the aid of Six Sigma when it comes to making sure that the results of handling metal and other related materials are correctly done. It ensures the continued provision of accurate and quality products and services to the public.


Introduction to Six Sigma in Metal Industry

Considering the numerous positive things and feedback that Six Sigma can do, it is no longer surprising if it ultimately means several things to different people. It was actually started and introduced by Motorola in the year 1990s. Presently, many people view it as a powerful management approach or methodology which centers on quality. As a popular and powerful management system, its main focus is to increase quality by ensuring that there are only 3.4 defects for every one million opportunities. In the metal industry where quality and accuracy is of topmost concern, this focus on quality by Six Sigma is extremely beneficial. Implementing Six Sigma in metal industry with the help of a Six Sigma Black Belt or any other expert and knowledgeable Six Sigma certification holder can definitely help you when it comes to sustaining the highest level of quality.

How can Six Sigma Help Metal Industry?

One of the many things that Six Sigma in metal industry can do is to guide the correct and high quality execution of the sheet metal forming process. This is considered to be among the most extensively used manufacturing processes in the metal industry. Note, however, that complex sheet metal deformation and improper process parameter design can result to defects including spring-back, wrinkling and fracture. The application of Six Sigma from the start up to the end of this process guarantees the full elimination of defects. It is also a major help in instantly predicting defects in the sheet metal formation process and in preventing the risk of consuming a lot of time in performing trial and error procedures. Note that the formation of metal in the metal industry with the help of the popular methodology adheres to Design for Six Sigma (DFSS). DFSS is also achievable in the metal industry with the help of the DMADOV approach. The application of DFSS along with the DMADOV in the metal industry typically follows a few steps represented by the following figure.

The table below also summarizes what the different steps associated to the DMADOV approach usually used along with the implementation of Design for Six Sigma in metal industry can do to make a company in this highly competitive industry grow.

Applying Six Sigma’s DMAIC Approach in the Metal Industry

The correct application of Six Sigma in metal industry also requires extensive understanding of the DMAIC approach. It helps dramatically boost the quality of the production and manufacturing processes used in this specific field, significantly reduce mistakes and defects and ensure that there is no impending or current loss in metal. The steps of the DMAIC approach along with their most useful tools that you can also utilize to get the most desirable results from Six Sigma in metal industry are indicated in the next figure.

The DMAIC approach which is widely used in Six Sigma implementation can benefit the metal industry especially in the process of eliminating or reducing metal losses through the following:

  • Define. The definition stage involves the proper utilization of the most effective and powerful tools especially those that are mentioned above in creating a list of the probable causes of the major losses of metal. It establishes the baseline of a process.
  • Measure. This step involves the evaluation of probable causes of losses with the help of statistical tools proven to be effective in properly keeping track of metrics. The step also involves the listing and evaluation of mass balance premises.
  • Analyze. It aims to completely analyze the results of the performed measurements and identifying the main and real causes of metal losses. It works by redefining calculation methodologies while also identifying the products and wastes associated to metal losses.
  • Improve. This step aims to implement improvement actions based upon the conclusions generated from the analyze phase. It aims to define process actions that guarantee the elimination of physical losses during typical or normal operations, determine specialized procedures that can help in minimizing physical losses during the decontamination of metal equipment and use estimated values as a means of evaluating metal losses during the mass balance.
  • Control. It primarily focuses in controlling the process improvements made and in making sure that these improvements continue to offer the best results in the metal industry.

DMAIC along with the other tools and approaches used for the proper application of Six Sigma in metal industry at present often result to more than 82% process improvement as shown in the following figure which is mainly based on the studies made by a formidable and successful metal company.

Final Thoughts on Six Sigma in Metal Industry

As a well-disciplined quality and process improvement methodology which takes advantage of statistical and data analysis when it comes improving and measuring the operational performance of a company through the immediate identification and complete elimination of defects in vital processes, you have a guarantee that the implementation of Six Sigma in metal industry can offer growth and development. It ensures the sustainable manufacturing of metals while also ensuring that essential resources are efficiently used. The method also helps in allowing professionals and experts in the Six Sigma industry to identify the procedures involved in manufacturing industrial metals productively and cost-efficiently while also ensuring that the least amount of wastes is visible. All these advantages make Six Sigma an extremely important philosophy, metric and methodology in the metal industry.

Six Sigma Black Belt Certification- $150 |  Six Sigma Master Black Belt Certification- $150
Six Sigma Master Implementer- $150  |  Six Sigma Green Belt Certification- $85

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