Scrap Reduction: By Six Sigma Methodology In Marwa Mineral Water Company

The purpose of this project was twofold – to learn the procedures and processes of the Six Sigma methodology, and to apply these methodologies in a real-world application. The first component of this project consisted of a thorough literature review of Six Sigma through a detailed examination of journals, books and case studies. The second component of this project was the application of these methodologies to a production line at Marwa Mineral Water company, in order to reduce the amount of scrap. This manufacturing problem was approached by the principle DMAIC methodology of Six Sigma, with Six Sigma tools such as SPC, ANOVA and FMEA used for analysis. These tools were used to identify significant factors which caused increased Scrap generation, and recommendations for improvement, such as the implementation of Line Monitoring Equipment, were provided thereafter. Techniques for control such as training and monitoring were also provided, to ensure the sustainability of any process improvements achieved through the Six Sigma Methodology. Six Sigma implementation reduced the scrap rate for bottles by 72.48% when changing the source of the raw material and other improvements, and increased the sigma level from 3.21 to 3.76 for bottles of 1.5 liter product in Marwa Mineral Water company . as result of the improvement , we enhance the following :
- Reducing the amount of money loss due to scrap .
- Reducing the amount of scrap in caps ,and labels .
- Reducing time lost in stopping of machines because of raw material.
- Improve the quality of product and reduce the effort lost in the inspection process .

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