Abstract

This study uses the application of the Six Sigma DMAIC (Define, Measure, Analyze, Improve, Control) methodology to significantly reduce the defect rate of Conical Lighting Poles (CLPs). A high CLP defect rate directly impacted profitability and customer satisfaction, prompting the need for a structured improvement initiative. Utilizing the DMAIC framework, the problem and its impact were defined. The measure phase involved data collection to quantify the current defect levels. In the analyze phase, a cause-and-effect analysis was conducted to identify root causes, with Pareto charts highlighting the most significant contributors to defects. Furthermore, a brainstorming session with experts from manufacturing, quality control, and maintenance departments facilitated the development of targeted solutions in the improve phase. The control phase implemented measures to sustain the improvements. The results successfully demonstrate the efficacy of the DMAIC methodology, leading to a substantial improvement in Pp and Ppk, which increased from 3.23 to 6.22. In addition, the process achieved statistical control with no out-of-control points, indicating a more stable and capable manufacturing process. This research not only reduced defects but also enhanced overall operational efficiency and product quality.

Key words: Six Sigma, Quality, DMAIC Phases, and Manufacturing Process