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Reliability deployment in distributed manufacturing chains via closed-loop Six Sigma methodology

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  • Jin, Tongdan
  • Janamanchi, Balaji
  • Feng, Qianmei

Abstract

This paper proposes a Six Sigma based framework to deploy high product reliability commitment in distributed subcontractor manufacturing processes. The study aims to expand the Six Sigma tools in applications, where products are designed and developed under the fast time-to-market requirement. The reliability deployment is driven by two incentives: the customer satisfaction and the reduction of the warranty cost. A closed-loop control mechanism is created between the upper and the lower manufacturing streams to identify and remove the early life failures occurred during the initial system installation. A cross-functional team is formed to implement Six Sigma tools for resolving critical failures arising in the upper manufacturing stream. The ultimate goal is to achieve high product reliability in the shortest time when the product time-to-market is essential for gaining the market share. Finally, the proposed control mechanism is demonstrated on the system designs drawn from the semiconductor testing industry.

Suggested Citation

  • Jin, Tongdan & Janamanchi, Balaji & Feng, Qianmei, 2011. "Reliability deployment in distributed manufacturing chains via closed-loop Six Sigma methodology," International Journal of Production Economics, Elsevier, vol. 130(1), pages 96-103, March.
    • Handle: RePEc:eee:proeco:v:130:y:2011:i:1:p:96-103
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    References listed on IDEAS

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    1. Yu, Hong-Fwu & Yu, Wen-Ching, 2007. "An optimal mixed policy of inspection and burn-in and the optimal production quantity," International Journal of Production Economics, Elsevier, vol. 105(2), pages 483-491, February.
    2. Kumar, U. Dinesh & Nowicki, David & Ramirez-Marquez, Jose Emmanuel & Verma, Dinesh, 2008. "On the optimal selection of process alternatives in a Six Sigma implementation," International Journal of Production Economics, Elsevier, vol. 111(2), pages 456-467, February.
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    Cited by:

    1. Khan, Samir & Phillips, Paul & Jennions, Ian & Hockley, Chris, 2014. "No Fault Found events in maintenance engineering Part 1: Current trends, implications and organizational practices," Reliability Engineering and System Safety, Elsevier, vol. 123(C), pages 183-195.
    2. Khan, Samir & Phillips, Paul & Hockley, Chris & Jennions, Ian, 2014. "No Fault Found events in maintenance engineering Part 2: Root causes, technical developments and future research," Reliability Engineering and System Safety, Elsevier, vol. 123(C), pages 196-208.
    3. Kristianto, Yohanes & Gunasekaran, Angappa & Helo, Petri, 2017. "Building the “Triple R” in global manufacturing," International Journal of Production Economics, Elsevier, vol. 183(PC), pages 607-619.
    4. Anshu Gupta & Pallavi Sharma & Akansha Jain & Hongbo Xue & S. C. Malik & P. C. Jha, 2023. "An integrated DEMATEL Six Sigma hybrid framework for manufacturing process improvement," Annals of Operations Research, Springer, vol. 322(2), pages 713-753, March.
    5. Chen, Xiangpeng & Wang, Rongxi & Gao, Jianmin, 2023. "An optimization framework for enterprise quality infrastructure system under coupling constraints," International Journal of Production Economics, Elsevier, vol. 262(C).
    6. Ahmet Erkoyuncu, John & Khan, Samir & Hussain, Syed Mohammed Fazal & Roy, Rajkumar, 2016. "A framework to estimate the cost of No-Fault Found events," International Journal of Production Economics, Elsevier, vol. 173(C), pages 207-222.

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