The primary goal of employing the improvement model referred to as Six Sigma is to limit variations in organizational outcomes whether as a transaction, product, or process. Through the application of statistical methods, any operating entity can use Six Sigma to enhance system performance (Stevenson, 2018). It was first developed as a quality control measurement tool towards improving the manufacturing and inspection processes at Motorola given that conventional means failed to detect and rectify defects (Stevenson, 2018). Statisticians employ the Greek alphabet, Sigma (σ) to represent standard deviation. Six Sigma translates to six standard deviations which entail working towards 3.4 defects for every one million outcomes (Stevenson, 2018). By studying the application of Six Sigma in an Egyptian plastic molding company, it is evident that quality of the end product is considerably enhanced thus allowing for cost effective operational processes, satisfied customers, and cleaner environment.
An Inefficient Plastic Injection Molding Process
The development of modern day plastics continues to be kept afloat by strong consumer demand. However, as witnessed in the Egyptian plant, plastic production techniques are often faced with challenges in achieving consistently good quality products (Maged et al., 2019). The company identifies the plastic injection molding process as a critical production phase. It involves the conversion of hot melt into pre-designed plastic products for specific purposes. Raw thermoplastic material is first melted before injection at immense pressure into a pre-designed cast. The Egyptian firm sells products with plastic parts like irons, fans, choppers, and blowers (Maged et al., 2019). The largest manufacturing process within the company involves the production of a diverse array of plastic components.
Unfortunately, it is common to encounter numerous plastic injection molding processes producing unfavorable outcomes. These include the production of huge quantities of defective plastic parts (Maged et al., 2019). These non conforming parts cannot be used in the rest of the production process and are thus considered as plastic scrap. The Egyptian firm terms such outcomes as being very costly in terms of time and organization resources, especially when it comes to reclaiming them for reuse (Maged et al., 2019). The firm is also keen on conforming to environmental regulations put in place by the Egyptian government. This involves ensuring that waste management processes attain high levels of efficiency when disposing defective materials. The best way to cut back on operational losses and to keep in line with government regulations is for the firm to lower the rate of production relative to plastic scrap (Maged et al.