International Business Management 10 (5): 676-691, 2016 ISSN: 1993-5250 © Medwell Journals, 2016 Corresponding Author: Rohail Hassan, Department of Management and Humanities, Universiti Teknologi PETRONAS (UTP), Tronoh, 31750 Perak, Malaysia 676 Application of Six-Sigma for Process Improvement in Manufacturing Industries: A Case Study Rohail Hassan, Maran Marimuthu and Manmeet Mahinderjit-Singh 1 1 2 Department of Management and Humanities, 1 Universiti Teknologi PETRONAS (UTP), Tronoh, Malaysia School of Computer Science, Universiti Sains Malaysia, 18000 Pulau Pinang, Malaysia 2 Abstract: This is an era of quality management and quality is a parameter for the selection of a product or service because the customer wants a defects free product or service. Six-Sigma is a quality improvement approach that aims to reduce the number of defects up to 3.4 parts per million. In the last three decades, it helped several companies to enhance the capability of their processes and to increase the level of quality of their product or service. This case study based research deals with application of DMAIC (Define, Measure, Analyze, Improve and Control) methodology of Six-Sigma to reduce the machine downtime for process improvement. The tools and techniques used during the analysis are Process Mapping (SIPOC Diagram), Process Flow Chart, Process Capability Analysis, Histogram, Pareto Chart, Pie Chart, Cause and Effect Diagram, Brainstorming, Affinity Diagram and ANOVA. The results of this study show that sigma value has improved from 2.79-2.85 Sigma. This study also highlighted the five critical problems (reasons) of downtime which are, i.e., electricity problem, shortage of material, quality issues, machine fault and reactive maintenance. The valuable principles and practices of Six-Sigma will do well by continuously refining the organizational culture. Time and commitment both are required and compulsory to bring change in cultural before they are strongly implanted into the organization. I do assure that this research study will provide opportunities to the organizations for the better implementation of Six-Sigma projects. Key words: Six-Sigma, project management, organizational culture, quality, process improvement INTRODUCTION expectations of the stakeholders for low price, the demand Six-Sigma is a big breakthrough in the field of quality competitive pressure. So, according to my point of view which is equally applicable in manufacturing and service the Six-Sigma is the most latest and successful method to sectors. The philosophy of Six-Sigma is to satisfy the describe, evaluates, examine, develop and manage the customer by offering the defect free product or service quality and efficiency of the any process, product or delivering on time at lower cost. The methodology of service. This part explains the interest why we selected Six-Sigma does not only improve the quality of a product the topic of Six-Sigma for my research project and what or service but it also focuses upon the cost of goods sold aim, objectives and outcomes are set to achieve from and the return on investment. A number of quality this research moreover what research methodology and programs have practiced over the last 25 years starting Six-Sigma tools are used for analysis and improvement. from Quality Circles (QC), “Statistical Process Control (SPC)”, “Total Quality Management (TQM)”, “ISO”, etc. Purpose of the study: The aim of this research study is the Some few reengineering concepts brought in practice application of Six-Sigma to reduce the machine downtime along with the above said programs like kaizen and lean for process improvement. manufacturing. With the proper implementation of these quality programs, many manufacturing companies got Planned objectives of the research study: The creation, financial benefits through lowering the cost of poor invention and research of everything have some definite quality, reduced their cycle time and decreased the ratio objectives behind that concept. Nothing is superfluous, of their customers’ complaints. After that, a breakthrough waste and useless in this world. With the application of approach was required in business to fulfill the high Six-Sigma, the following objectives will achieve: for defect free product or service and to meet the