Quality assurance and excellence in a university pilot plant

Abstract

Excellence is achieved through continuous improvement, and the most widely used methodology for continuous improvement is Lean Six Sigma. This dissertation aims to evaluate whether the tools that compose Lean Six Sigma can be applied in a university pilot plant. Taking the SDM as a reference, two processes were chosen, and two Lean Six Sigma tools were applied to each of these processes. The time taken to resolve deviations and the quality of documentation were chosen because they had been quality indicators at SDM for several years, which had reflected their importance to the pilot plant. An Ishikawa diagram aided in identifying possible factors contributing to a late resolution of deviations. The subsequent failures modes and effects analysis effectively helped to identify different failures modes and set a risk number to help prioritize the suggested preventive actions to take. Similarly, for the quality of documentation, brainstorming aided in identifying weaknesses and improvement opportunities. The ensuing 5 whys analysis helped pick the possible main obstacles to achieving a high level of client satisfaction with the quality of documentation. Both analysis processes identified personnel as a limitation due to high rotation and the deficient involvement, and training. However, improvement opportunities have been detected as well; the use of FMEA can be helpful in resolving complex deviations, and the improvement of the digital organization system can help attain higher quality documentation. Key words: excellence, continuous improvement, lean six sigma, pilot plant.