Development and validation of DMAIC based framework for process improvement: a case study of Indian manufacturing organization

Purpose The purpose of this paper is to develop and validate an extended Define-Measure-Analyze-Improve-Control (DMAIC) based framework through a case study of an Indian fasteners manufacturing organization. Design/methodology/approach Research methodology is established on the development of the existing DMAIC framework through an extensive literature review of 25 LSS/DMAIC based frameworks and discussions held with practitioners. This paper also depicts a case study of Indian manufacturing organization for validation of the developed framework. Findings The study proposed an extended DMAIC based framework for effective implementation of Lean Six Sigma (LSS) methodology. Furthermore, this framework has been implemented successfully in the Indian manufacturing organization and showed encouraging results. The in-house rejections of Nut Cylinder Head (NCH) were brought down to 966 from 2910 PPM and sigma level was improved by 0.40. The case organization has achieved significant improvements in the process capability, customer satisfaction, and cost savings of US$ 0.25 million in one financial year. Intangible benefits like improvements in employee's morale, communication, housekeeping and decision-making capabilities were also observed significantly. Practical implications The proposed DMAIC based framework has been implemented successfully in the Indian case organization, and the results will enable the policymakers, specifically practitioners, to strategically leverage the resources for successful implementation of the LSS in healthcare, aerospace, service sectors etc. Originality/value This research develops a DMAIC based framework which can be used to implement LSS effectively in different industries. Moreover, the pre (initial/introduction) and post (validation/verification) implementation phase provides the top management, an edge to think strategically into broader improvement areas.