An Application of Six Sigma to Reduce Waste

Six Sigma has been considered a powerful business strategy that employs a wellstructured continuous improvement methodology to reduce process variability and drive out waste within the business processes using effective application of statistical tools and techniques. Although there is a wider acceptance of Six Sigma in many organizations today, there appears to be virtually no in-depth case study of Six Sigma in the existing literature. This involves how the Six Sigma methodology has been used, how Six Sigma tools and techniques have been applied and how the benefits have been generated. This paper presents a case study illustrating the effective use of Six Sigma to reduce waste in a coating process. It describes in detail how the project was selected and how the Six Sigma methodology was applied. It also shows how various tools and techniques within the Six Sigma methodology have been employed to achieve substantial financial benefits. Copyright c © 2005 John Wiley & Sons, Ltd.