Process Optimization: A Six Sigma DMAIC Approach
Nap fabrics used in paint roller covers are required to meet nap height specifications measured as the overall fabric thickness from its backing to meet substrate paint application standards. Consistency in heat setting process is key to achieving customer specifications for nap fabrics. Excessive shrinkage or variation in shrinkage during heat setting will lead to nonconforming nap fabric heights and costly adjustments, tweaking for quality or downgrading in downstream finishing processes. An exploratory analysis in the measure phase revealed significant difference in yarn shrinkage levels between suppliers. Effect of supplier and heat setting temperature levels on yarn shrinkage was statistically significant, F(2,42)=19.78, P= .000. These exploratory results reveals evidence of significant vendor factor contribution to process variability. This paper will discuss the six sigma DMAIC tools applied in this project and highlight results and opportunities for process optimization, improvement and controls applied to meet expected annualized savings.
Presented online for the 2016 Research and Creative Achievement Week. Blog website: http://blog.ecu.edu/sites/davidkurgatt/