Process Optimization: A Six Sigma DMAIC Approach
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Date
2016-04
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Authors
Kurgatt, David
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Abstract
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.
Description
Presented online for the 2016 Research and Creative Achievement Week. Blog website: http://blog.ecu.edu/sites/davidkurgatt/