IDEAS home Printed from https://ideas.repec.org/a/spr/ijsaem/v13y2022i1d10.1007_s13198-021-01199-4.html
   My bibliography  Save this article

Product development using Design for Six Sigma approach: case study in switchgear industry

Author

Listed:
  • Sainath G. Bidikar

    (Sardar Patel College of Engineering)

  • Santosh B. Rane

    (Sardar Patel College of Engineering)

  • Prathamesh R. Potdar

    (Rajiv Gandhi Institute of Technology)

Abstract

The competitive business environment conditions of market have compelled to reduce the development period of products; therefore, organizations are more focused on optimizing product development period to satisfy customers' needs quickly. This study aims to shorten the development period of moulded case circuit breaker (MCCB) using design for Six Sigma (DFSS) approach and ensure sustainable product development using reliability analysis. In this study, the DFSS approach has been demonstrated using define measure analyze design and verify (DMADV) methodology with appropriate tools and techniques at each stage for the development of MCCB. The mechanical endurance test (MET), electrical endurance test (EET) and temperature rise test (TRT) have been performed to ensure the sustainability of the developed MCCB. The comparative analysis of the TRT results of the existing and uprated MCCB shows the reduction in temperature rise by 10 °C at the terminal. The efforts and time required for product development have been reduced due to the uprating of existing MCCB and reliability of uprated MCCB is computed as 98.44% by analyzing collected data using Weibull distribution. The analysis shows the wear-out failure of MCCB components as the shape factor value of the Weibull distribution is greater than one. This study concludes that every organization should critically reinvestigate the product to explore the opportunity for improving the quality and functionality of the product using appropriate tools and techniques. This case study clearly shows improvement in product reliability and quality which results in cost-saving business.

Suggested Citation

  • Sainath G. Bidikar & Santosh B. Rane & Prathamesh R. Potdar, 2022. "Product development using Design for Six Sigma approach: case study in switchgear industry," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 13(1), pages 203-230, February.
    • Handle: RePEc:spr:ijsaem:v:13:y:2022:i:1:d:10.1007_s13198-021-01199-4
    DOI: 10.1007/s13198-021-01199-4
    as

    Download full text from publisher

    File URL: http://link.springer.com/10.1007/s13198-021-01199-4
    File Function: Abstract
    Download Restriction: Access to the full text of the articles in this series is restricted.
    File URL: https://libkey.io/10.1007/s13198-021-01199-4?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    1. Jiju Antony, 2012. "A SWOT analysis on Six Sigma: some perspectives from leading academics and practitioners," International Journal of Productivity and Performance Management, Emerald Group Publishing Limited, vol. 61(6), pages 691-698, July.
    2. Santosh B. Rane & Prathamesh R. Potdar & Suraj Rane, 2019. "Accelerated life testing for reliability improvement: a case study on Moulded Case Circuit Breaker (MCCB) mechanism," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 10(6), pages 1668-1690, December.
    3. Dilbagh Panchal & Priyank Srivastava, 2019. "Qualitative analysis of CNG dispensing system using fuzzy FMEA–GRA integrated approach," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 10(1), pages 44-56, February.
    4. Vadivel Sengazani Murugesan & A. H. Sequeira & Sunil Kumar Jauhar & Vimal Kumar, 2020. "Sustainable postal service design: integrating quality function deployment from the customers perspective," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 11(2), pages 494-505, April.
    5. Ajinkya Shirurkar & Yogesh Patil & D. Davidson Jebaseelan, 2019. "Reliability improvement of fork biasing spring in MCCB mechanism," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 10(4), pages 491-498, August.
    6. Mohammad Pourgol-Mohammad & Amirmohsen Hejazi & Morteza Soleimani & Pejman Ghasemi & Alireza Ahmadi & Davoud Jalali-Vahid, 2017. "Design for reliability of automotive systems; case study of dry friction clutch," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 8(3), pages 572-583, September.
    7. Santosh B. Rane & Yahya A.M. Narvel & Niloy Khatua, 2017. "Development of mechanism for mounting secondary isolating contacts (SICs) in air circuit breakers (ACBs) with high operational reliability," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 8(2), pages 1816-1831, November.
    8. M. Karthikeyan & V. N. A. Naikan & R. Narayan, 2017. "Root cause analysis and reliability improvement methods for orbital TIG welding process for propulsion feed system of satellites," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 8(2), pages 910-924, November.
    9. Santosh B. Rane & Milind Shrikant Kirkire, 2017. "Interpretive structural modelling of risk sources in medical device development process," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 8(1), pages 451-464, January.
    10. Amir Abbas Shojaie & Elahe Kahedi, 2019. "Auto parts manufacturing quality assessment using design for six sigma (DFSS), case study in ISACO company," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 10(1), pages 35-43, February.
    11. Santosh B. Rane & Yahya A. M. Narvel, 2016. "Reliability assessment and improvement of air circuit breaker (ACB) mechanism by identifying and eliminating the root causes," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 7(1), pages 305-321, December.
    12. Santosh B. Rane & Nandkumar Mishra, 2018. "Roadmap for business analytics implementation using DIPPS model for sustainable business excellence: case studies from the multiple fields," International Journal of Business Excellence, Inderscience Enterprises Ltd, vol. 15(3), pages 308-334.
    13. Anil Kr. Aggarwal & Sanjeev Kumar & Vikram Singh, 2017. "Mathematical modeling and reliability analysis of the serial processes in feeding system of a sugar plant," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 8(1), pages 435-450, January.
    14. Shiva Mehrabi-Kandsar & Abolfazl Mirzazadeh & Aref Gholami-Qadikolaei, 2017. "The quality function deployment method under uncertain environment using evidential reasoning: a case study of compressor manufacturing," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 8(2), pages 1867-1884, November.
    15. Luis Alberto Rodríguez-Picón & Víctor Hugo Flores-Ochoa, 2017. "Estimation of a log-linear model for the reliability assessment of products under two stress variables," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 8(2), pages 1026-1040, November.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Santosh B. Rane & Sandesh Wavhal & Prathamesh R. Potdar, 2023. "Integration of Lean Six Sigma with Internet of Things (IoT) for productivity improvement: a case study of contactor manufacturing industry," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 14(5), pages 1990-2018, October.

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Santosh B. Rane & Sandesh Wavhal & Prathamesh R. Potdar, 2023. "Integration of Lean Six Sigma with Internet of Things (IoT) for productivity improvement: a case study of contactor manufacturing industry," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 14(5), pages 1990-2018, October.
    2. Santosh B. Rane & Prathamesh R. Potdar & Suraj Rane, 2019. "Accelerated life testing for reliability improvement: a case study on Moulded Case Circuit Breaker (MCCB) mechanism," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 10(6), pages 1668-1690, December.
    3. Santosh B. Rane & Yahya Abdul Majid Narvel, 2022. "Data-driven decision making with Blockchain-IoT integrated architecture: a project resource management agility perspective of industry 4.0," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 13(2), pages 1005-1023, April.
    4. Santosh B. Rane & Yahya A. M. Narvel, 2021. "Leveraging the industry 4.0 technologies for improving agility of project procurement management processes," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 12(6), pages 1146-1172, December.
    5. Mehdi Salimi & Mahboubeh Khodaparast, 2019. "Providing a combined model of fuzzy AHP and numerical taxonomy analysis for sport organizational ranking and performance appraisal," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 10(5), pages 1133-1144, October.
    6. Rajiv Kumar Sharma, 2022. "Examining interaction among supplier selection strategies in an outsourcing environment using ISM and fuzzy logic approach," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 13(5), pages 2175-2194, October.
    7. Ricardo Andrés García-León & Wailer Jaimes-Gonzalez & Lili Dahiana Becerra & Eder Flórez-Solano & Malka Cabellos-Martínez & Daniel Meneses-Torres, 2021. "Application of the QFD method to the design of a cocoa pulping machine," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 12(6), pages 1199-1220, December.
    8. Tang, Xinzi & Wang, Zhe & Xiao, Peng & Peng, Ruitao & Liu, Xiongwei, 2020. "Uncertainty quantification based optimization of centrifugal compressor impeller for aerodynamic robustness under stochastic operational conditions," Energy, Elsevier, vol. 195(C).
    9. Ajinkya Shirurkar & Yogesh Patil & D. Davidson Jebaseelan, 2019. "Reliability improvement of fork biasing spring in MCCB mechanism," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 10(4), pages 491-498, August.
    10. Mehdi Tavakoli & Mehdi Nafar, 2021. "Modification of the FFTA method for calculating and analyzing the human reliability of maintenance groups in power transmission grids," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 12(6), pages 1221-1234, December.
    11. J. Wakiru & P. N. Muchiri & L. Pintelon & P. Chemweno, 2019. "A cost-based failure prioritization approach for selecting maintenance strategies for thermal power plants: a case study context of developing countries," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 10(5), pages 1369-1387, October.
    12. Mohamed Alawadhi & Jumah Almazrouie & Mohammed Kamil & Khalil Abdelrazek Khalil, 0. "Review and analysis of the importance of autonomous vehicles liability: a systematic literature review," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 0, pages 1-23.
    13. Anna Drab-Kurowska & Michal Kuscinski, 2023. "E-Services of National Postal Operators - A "Must Have" Current Times to Ensure the Functioning of the State's Critical Infrastructure," European Research Studies Journal, European Research Studies Journal, vol. 0(3), pages 523-533.
    14. Mehdi Allahdadi & Aida Batamiz, 2021. "Generation of some methods for solving interval multi-objective linear programming models," OPSEARCH, Springer;Operational Research Society of India, vol. 58(4), pages 1077-1115, December.
    15. M. Suresh & G. Mahadevan & R. Dev Abhishek, 2019. "Modelling the factors influencing the service quality in supermarkets," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 10(6), pages 1474-1486, December.
    16. Pan Wu & Guoyan Zhao & Yang Li, 2022. "Green Mining Strategy Selection via an Integrated SWOT-PEST Analysis and Fuzzy AHP-MARCOS Approach," Sustainability, MDPI, vol. 14(13), pages 1-19, June.
    17. Mohamed Alawadhi & Jumah Almazrouie & Mohammed Kamil & Khalil Abdelrazek Khalil, 2020. "Review and analysis of the importance of autonomous vehicles liability: a systematic literature review," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 11(6), pages 1227-1249, December.
    18. Sandeep Jadhav & Ahmed Imran & Marjia Haque, 2023. "Application of six sigma and the system thinking approach in COVID-19 operation management: a case study of the victorian aged care response centre (VACRC) in Australia," Operations Management Research, Springer, vol. 16(1), pages 531-553, March.
    19. Seán Paul Teeling & Jan Dewing & Deborah Baldie, 2021. "A Realist Inquiry to Identify the Contribution of Lean Six Sigma to Person-Centred Care and Cultures," IJERPH, MDPI, vol. 18(19), pages 1-21, October.
    20. Noor Asfia & Muhammad Usman Awan & Shahid Munir, 2022. "Halal Meat Exports Enhancement of Pakistan: An Intermediating Role of Global Technical Standards in Quality Function Deployment Model," Journal of Economic Impact, Science Impact Publishers, vol. 4(1), pages 59-70.

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:spr:ijsaem:v:13:y:2022:i:1:d:10.1007_s13198-021-01199-4. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Sonal Shukla or Springer Nature Abstracting and Indexing (email available below). General contact details of provider: http://www.springer.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.