Quality Management: Application of the DMAIC Tool to Prevent Paint Rework on Excavator Buckets
DOI:
https://doi.org/10.12776/qip.v30i1.2279Keywords:
quality management, Lean Six Sigma, DMAIC, continuous improvement, zero defectsAbstract
Purpose: This work aims to apply the DMAIC methodology to solve a problem of paint rework on buckets during the storage process at a heavy machinery company in the South of Rio de Janeiro.
Methodology/Approach: The technical procedures adopted for the research are based on the case study approach. This methodological classification allows for an in-depth and detailed investigation of a singular case.
Findings: With this solution, we were able to reduce rework and consequently cut the costs of re-painting parts, which can also be highlighted as the main applied contribution of this work, since these results can support other companies that will go through the same process.
Research Limitation/Implication: It is important to note that there was not enough time to collect results after implementing the device. For future research, it is suggested that the company continue to invest in continuous improvement processes, using methodologies with different approaches.
Originality/Value of paper: The need to avoid painting rework, due to the associated costs, highlights the importance of the structured approach proposed. Data analysis showed that more than 40% of the buckets produced by the company had paint scratches, generating 63 hours of rework and a cost of R$ 124,988.51.
References
Achibat, F. E., Lebkiri, A., Aouane, E. M., Lougraimzi, H., Berrid, N., & Maqboul, A. (2023). Analysis of the impact of Six Sigma and Lean Manufacturing on the performance of companies. Management Systems in Production Engineering, 31(2), 191–196. https://doi.org/10.2478/mspe-2023-0020
Adeodu, A., Maladzhi, R., Kana-Kana Katumba, M. G., & Daniyan, I. (2023). Development of an improvement framework for warehouse processes using lean six sigma (DMAIC) approach: A case of third party logistics (3PL) services. Heliyon, 9(4), e14915. https://doi.org/10.1016/j.heliyon.2023.e14915
Alshamlan, M., Alzahrani, A., BinYousef, M., Abdelhadi, A., Akkad, K., & Alyamani, R. (2022). Optimization for sustainable train shunting services using DMAIC cycle. Sustainability, 14(3), 1719. https://doi.org/10.3390/su14031719
Amitrano, F. G., Estorilio, C. C. A., de Oliveira Franzosi Bessa, L., & Hatakeyama, K. (2016). Six Sigma application in small enterprise. Concurrent Engineering, 24(1), 69–82. https://doi.org/10.1177/1063293X15594212
Azevedo, J., Sá, J. C., Ferreira, L. P., Santos, G., Cruz, F. M., Jimenez, G., & Silva, F. J. G. (2019). Improvement of production line in the automotive industry through lean philosophy. Procedia Manufacturing, 41, 1023–1030. https://doi.org/10.1016/j.promfg.2019.10.029
Bai, Y., Liu, J., Zhang, R., & Bai, X. (2023). Quality control of water-efficient products based on DMAIC improved mode—A case study of smart water closets. Processes, 11(1), 131. https://doi.org/10.3390/pr11010131
Bonetti, S. de A., Bueno, A., Silva, R. B. Z. da, Paredes, F. J. G., & Bianco, D. (2023). Using DMAIC for in-plant logistic activities improvement. Brazilian Journal of Operations & Production Management, 20(4), 1406. https://doi.org/10.14488/BJOPM.1406.2023
Castro, C., Pereira, T., Sá, J. C., & Santos, G. (2020). Logistics reorganization and management of the ambulatory pharmacy of a local health unit in Portugal. Evaluation and Program Planning, 80, 101801. https://doi.org/10.1016/j.evalprogplan.2020.101801
Chen, K.-S., Ye, G.-P., Yu, C.-M., & Yu, C.-H. (2023). Construct the optimum process model for transistor gaskets with Six-Sigma DMAIC. Applied Sciences, 13(12), 6895.https://doi.org/10.3390/app13126895.
Chero Yenque, F. A., Rodriguez Bazan, T. M., Miñan Olivos, G. S., & Valderrama-Puscan, M. W. (2022). Sigma methodology and its effect on quality: A systematic review of the literature between 2010-2020 in industrial companies. In Proceedings of the 20th LACCEI International Multi-Conference for Engineering, Education and Technology (pp. 1–7). https://doi.org/10.18687/LACCEI2022.1.1.117
Condé, G. C. P., Oprime, P. C., Pimenta, M. L., Sordan, J. E., & Bueno, C. R. (2023). Defect reduction using DMAIC and Lean Six Sigma: A case study in a manufacturing car parts supplier. International Journal of Quality & Reliability Management, 40(9), 2184–2204. https://doi.org/10.1108/IJQRM-05-2022-0157
Craveiro, A., Lima, V., Santos, G., Sá, J. C., Lopes, M., & Carvalho, J. D. (2023). Lean and Six Sigma philosophies and organizational performance: A study in Portuguese laboratories. Quality Innovation Prosperity, 27(1), 21–45. https://doi.org/10.12776/QIP.V27I1.1802
Cronin, M. A., & George, E. (2023). The why and how of the integrative review. Organizational Research Methods, 26(1), 168–192. https://doi.org/10.1177/1094428120935507
Enache, I.-C. C., Chivu, O. R., Rugescu, A.-M. M., Ionita, E., & Radu, I. V. (2023). Reducing the Scrap Rate on a Production Process Using Lean Six Sigma Methodology. Processes, 11(4), 1295.https://doi.org/10.3390/pr11041295
Escobar, C. A., Macias, D., McGovern, M., Hernandez-de-Menendez, M., & Morales-Menendez, R. (2022). Quality 4.0 – an evolution of Six Sigma DMAIC. International Journal of Lean Six Sigma, 13(6), 1200-1238. https://doi.org/10.1108/IJLSS-05-2021-0091
Escobar, C. A., Macias-Arregoyta, D., & Morales-Menendez, R. (2023). The decay of Six Sigma and the rise of Quality 4.0 in manufacturing innovation. Quality Engineering, 1–20. [Advance online publication]. https://doi.org/10.1080/08982112.2023.2206679
Godina, R., Silva, B. G. R., & Espadinha-Cruz, P. (2021). A DMAIC integrated fuzzy FMEA model: A case study in the automotive industry. Applied Sciences, 11(8), 3726. https://doi.org/10.3390/app11083726
Gomes, F. da S., Camargo, P. R., Reis, J. S. da M., Diogo, G. M. M., Cardoso, R. P., Barros, J. G. M. de, Santos, G. (2022). The main benefits of application of Six Sigma for productive excellence. Quality Innovation Prosperity, 26(3), 151-167. https://doi.org/10.12776/qip.v26i3.1712
Hamdan, A., Hamdan, S., Alsyouf, I., Murad, N., Abdelrazeq, M., Al‐Ali, S., & Bettayeb, M. (2024). Enhancing sustainability performance of universities: A DMAIC approach. Systems Research and Behavioral Science, 41(1), 153-172. https://doi.org/10.1002/sres.2942
Hannafin, C., Ponce, L., Dahiya, N., Utecht, C., DeYoung, D., & Flug, J. (2023). DMAIC quality improvement project to reduce specimen-related safety events in ultrasound. Current Problems in Diagnostic Radiology, 52(6), 469-473. https://doi.org/10.1067/j.cpradiol.2023.06.008
Hollingshed, M. (2022). Standardizing Six Sigma Green Belt training: Identification of the most frequently used measure phase DMAIC tools. International Journal of Lean Six Sigma, 13(2), 276-294. https://doi.org/10.1108/IJLSS-12-2020-0220
Jirasukprasert, P., Arturo Garza-Reyes, J., Kumar, V., & Lim, M. K. (2014). A Six Sigma and DMAIC application for the reduction of defects in a rubber gloves manufacturing process. International Journal of Lean Six Sigma, 5(1), 2-21. https://doi.org/10.1108/IJLSS-03-2013-0020
Khalilinezhad, S., Fazlollahtabar, H., Minaei-Bidgoli, B., & Nosratabadi, H. E. (2021). Detecting valuable customers using the trade patterns of financial transactions applying integrated RFM and OLAP. International Journal of Industrial Engineering and Production Research, 32(3), 1-18. https://doi.org/10.22068/ijiepr.32.3.1
Knop, K. (2022). Using Six Sigma DMAIC cycle to improve workplace safety in the company from automotive branch: A case study. Manufacturing Technology, 22(3), 297-306. https://doi.org/10.21062/mft.2022.040
Kothari, C. R., & Garg, G. (2019). Research methodology: Methods and techniques (4th ed.). New Delhi, India: New Age International.
Kumar, R., Kumar, K., Singh, R., Sá, J. C., Carvalho, S., & Santos, G. (2023). Modeling environmentally conscious purchase behavior: Examining the role of ethical obligation and green self-identity. Sustainability, 15(8), 6426. https://doi.org/10.3390/su15086426
Makinde, O., Selepe, R., Munyai, T., Ramdass, K., & Nesamvuni, A. (2022). Improving the supply chain performance of an electronic product-manufacturing organisation using DMAIC approach. Cogent Engineering, 9(1), 2025196. https://doi.org/10.1080/23311916.2021.2025196
Mandal, P. (2012). Improving process improvement: Executing the analyze and improve phases of DMAIC better. International Journal of Lean Six Sigma, 3(3), 231-250. https://doi.org/10.1108/20401461211282727
Miguel, P. A. C. (2018). Metodologia de pesquisa para engenharia de produção e gestão de operações (3rd ed.). Rio de Janeiro, Brazil: Elsevier.
Mittal, A., Gupta, P., Kumar, V., Al Owad, A., Mahlawat, S., & Singh, S. (2023). The performance improvement analysis using Six Sigma DMAIC methodology: A case study on Indian manufacturing company. Heliyon, 9(3), e14625. https://doi.org/10.1016/j.heliyon.2023.e14625
Murmura, F., Bravi, L., & Santos, G. (2021). Sustainable process and product innovation in the eyewear sector: The role of Industry 4.0 enabling technologies. Sustainability, 13(1), 365. https://doi.org/10.3390/su13010365
Neeru, Rajput, N. S., & Patil, A. (2023). Reducing oil leakage in heavy duty transformers made in small-scale manufacturing industry through Six Sigma DMAIC: A case study for Jaipur. Evergreen, 10(1), 196-211. https://doi.org/10.5109/6781070
Pongboonchai-empl, T., Antony, J., Garza-Reyes, J. A. A., Tortorella, G. L. L., Komkowski, T., & Tortorella, G. L. L. (2023). Integration of Industry 4.0 technologies into Lean Six Sigma DMAIC: A systematic review. Production Planning & Control, [Advance online publication]. https://doi.org/10.1080/09537287.2023.2188496
Prado, R. R. Do, Boareto, P. A., Chaves, J., & Santos, E. A. P. (2023). Agile DMAIC cycle: Incorporating process mining and support decision. International Journal of Lean Six Sigma, 15(3), 614-641. https://doi.org/10.1108/IJLSS-04-2022-0092
Ramos, K., & Rodríguez, D. (2022). Implementation of DMAIC in the snacks’ manufacturing process. In Proceedings of the 20th LACCEI International Multi-Conference for Engineering, Education and Technology (pp. 1-7). https://doi.org/10.18687/LACCEI2022.1.1.686
Rebelo, M. F., Silva, R., Santos, G., & Mendes, P. (2016). Model based integration of management systems (MSs)-case study. The TQM Journal, 28(6), 907-932. https://doi.org/10.1108/TQM-09-2014-0079
Reis, J. S. da M., Espuny, M., Nunhes, T. V., Sampaio, N. A. de S., Isaksson, R., Campos, F. C. de, & Oliveira, O. J. de. (2021). Striding towards sustainability: A framework to overcome challenges and explore opportunities through Industry 4.0. Sustainability, 13(9), 5232. https://doi.org/10.3390/su13095232
Rodrigues, J., Sá, J. C., Silva, F. J. G., Ferreira, L. P., Jimenez, G., & Santos, G. (2020). A rapid improvement process through “quick-win” lean tools: A case study. Systems, 8(4), 1–19
Santos, G., Carvalho, S., Sá, J. C., & Ferreira, L. P. (2023). The Importance of Patent Registration in the Way of Generating Wealth for Nations. Flexible Automation and Intelligent Manufacturing: Establishing Bridges for More Sustainable Manufacturing Systems – FAIM 2023. Lecture Notes in Mechanical Engineering, 848–855.
Santos, G., Mandado, E., Silva, R., & Doiro, M. (2019). Engineering learning objectives and computer assisted tools. European Journal of Engineering Education, 44(4), 616-628. https://doi.org/10.1080/03043797.2018.1563585
Santos, G., & Millán, A. L. (2013). Motivation and benefits of implementation and certification according ISO 9001 - the Portuguese experience. International Journal for Quality Research, 7(1), 71–86.
Santos, G., Rebelo, M., Barros, S., Silva, R., Pereira, M., Ramos, G., & Lopes, N. (2014). Developments regarding the integration of the occupational safety and health with quality and environment management systems. In Occupational Safety and Health (pp. 113–146). Hauppauge, NY: Nova Science Publishers.
Ismail, S. A. S., As’arry, A., Sapuan, S. M., & Tarique, J. (2023). Improvement of plastic manufacturing processes by Six Sigma and DMAIC methods. Applied Science and Engineering Progress, 16(3), 020007. https://doi.org/10.14416/j.asep.2023.04.003
Silva, S., Sá, J. C., Silva, F. J. G., Ferreira, L. P., & Santos, G. (2020). Lean Green—The importance of integrating environment into lean philosophy—A case study. Lecture Notes in Networks and Systems, 122, 211–219. https://doi.org/10.1007/978-3-030-41429-0_21
Solanki, M., & Desai, D. (2021). Competitive advantage through Six Sigma in sand casting industry to improve overall first-pass yield: A case study of SSE. International Journal of Lean Six Sigma, 12(3), 477–502. https://doi.org/10.1108/IJLSS-03-2020-0032
Sun, Z., Doiro, M., Sá, J. C., & Santos, G. (2023). Shaping the conscious behaviors of product designers in the early stages of projects: Promoting correct material selection and green self-identity through a new conceptual model. Sustainability, 15(19), 14463. https://doi.org/10.3390/su151914463
Talapatra, S., Santos, G., & Gaine, A. (2022). Factors affecting customer satisfaction in eatery business - An empirical study from Bangladesh. International Journal for Quality Research, 16(1), 163–176. https://doi.org/10.24874/IJQR16.01-11
Teixeira, P., Coelho, A., Fontoura, P., Sá, J. C., Silva, F. J. G., Santos, G., & Ferreira, L. P. (2022). Combining lean and green practices to achieve a superior performance: The contribution for a sustainable development and competitiveness—An empirical study on the Portuguese context. Corporate Social Responsibility and Environmental Management, 29(4), 887–903.
Tsarouhas, P., & Sidiropoulou, N. (2023). Application of Six Sigma methodology using DMAIC approach for a packaging olives production system: A case study. International Journal of Lean Six Sigma, 15(2), 247–273. https://doi.org/10.1108/IJLSS-06-2022-0140
Tsarouhas, P. (2021). Reliability, availability and maintainability analysis of a bag production industry based on the Six Sigma DMAIC approach. International Journal of Lean Six Sigma, 12(2), 237–263. https://doi.org/10.1108/IJLSS-09-2019-0101
Tsung, F., & Wang, K. (2023). Six Sigma. In Springer handbook of engineering statistics (pp. 239–259). London, England: Springer London.
Uluskan, M., & Karşı, M. G. (2023). Predictive Six Sigma for Turkish manufacturers: Utilization of machine learning tools in DMAIC. International Journal of Lean Six Sigma, 14(3), 630–652. https://doi.org/10.1108/IJLSS-02-2022-0046
Uluskan, M. (2016). A comprehensive insight into the Six Sigma DMAIC toolbox. International Journal of Lean Six Sigma, 7(4), 406–429. https://doi.org/10.1108/IJLSS-10-2015-0040
Vieira, T., Sá, J. C., Lopes, M. P., Santos, G., Félix, M. J., Ferreira, L. P., Silva, F. J. G., & Pereira, M. T. (2019). Optimization of the cold profiling process through SMED. Procedia Manufacturing, 38, 892–899. https://doi.org/10.1016/j.promfg.2020.01.171
Yin, R. K. (2017). Case study research: Design and methods (6th ed.). Thousand Oaks, CA: SAGE Publications.
Yülek, M.A. & Santos, G. (2022). Why Income Gaps Persist: Productivity Gaps, (No) Catch-up and Industrial Policies in Developing Countries. Journal of Economic Issues, 56(1), 158–183. https://doi.org/10.1080/00213624.2022.2020579
Zgodavova, K., Bober, P., Majstorovic, V., Monkova, K., Santos, G., & Juhaszova, D. (2020). Innovative methods for small mixed batches production system improvement: The case of a bakery machine manufacturer. Sustainability, 12, 6266. https://doi.org/10.3390/su12156266
Downloads
Published
Issue
Section
License
Copyright (c) 2026 José Salvador da Motta Reis, Giovanna Caffaro das Chagas, Laryssa de Aragão Silva, Gilberto Santos, Luis Cesar Ferreira Motta Barbosa
This work is licensed under a Creative Commons Attribution 4.0 International License.
This is an open access journal which means that all content is freely available without charge to the user or his/her institution. Users are allowed to read, download, copy, distribute, print, search, or link to the full texts of the articles in this journal without asking prior permission from the publisher or the author. This is in accordance with the BOAI definition of open access. This journal is licensed under a Creative Commons Attribution 4.0 License - https://creativecommons.org/licenses/by/4.0.
Authors who publish with the Quality Innovation Prosperity agree to the following terms:
- Authors retain copyright and grant the journal right of first publication with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.
- Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.
- Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) prior to and during the submission process, as it can lead to productive exchanges, as well as earlier and greater citation of published work.
