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Applications in the Wine making industry

Nov 30, 2014

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The purpose of the paper is to improvise the six sigma process applied on the Wine making process using the TRIZ principles for the following problem.
The problem faced by the industry is that “Dry wines contain substances beneficial to human health; however, they cannot be given to children. The alcohol can be evaporated from the wine by boiling, but the high temperatures destroy the beneficial substances in the wine.”
Our approach to improve the process would be applying the 40 principles of TRIZ to the wine making process. The solution for the problem was found in the principles of physics using which used the concepts of pressure which are entirely outside the boundaries of wine making process.

Six Sigma and Triz

Welingkar institute of Management Development and Research, Mumbai

Six Sigma and Triz

Applications in the Wine making industry

Index3Abstract

5PART I

51.1What is Six Sigma?

51.2How does Six Sigma work?

71.3What is TRIZ?

81.4TRIZ tools

81.5Overcoming Lack of Solution Location

91.6Integration of I-TRIZ and Six Sigma methodologies generally leads to significantly

102PART II

102.1Application of six sigma & TRIZ to make non alcoholic wine, without compromising its medicinal properties.

112.2The need for TRIZ

122.3Application of TRIZ principles

162.4End result

172.5Cost Benefit Analysis

173Conclusion

AbstractExecutive Summary:

Six Sigma stands for Six Standard Deviations (Sigma is the Greek letter used to represent standard deviation in statistics) from mean. Six Sigma methodology provides the techniques and tools to improve the capability and reduce the defects in any existing process.

TRIZ is an established science, methodology, set of tools, and knowledge- and model-based technology for stimulating and generating innovative ideas and solutions from previously existing solutions of similar problems in different fields.

The paper focuses on finding solution to problem of making a low alcohol content wine for children to make use of the substances beneficial to the human health.

The limitations of Six Sigma process.

There are often significant delays in Six Sigma projects and intermediate deliveries. One of the most frequent reasons is decision-making errors that lead to rework and time-consuming data collection activities. Various such problems are found in each step of the six sigma approach. For e.g., the problems found in the design and identification phase of Six Sigma application process are:

Define/Identify Phases Poor project selection and/or problem formulation

Non-exhaustive list of potential directions for change and/or for innovation

Originally, TRIZ process was used for the manufacturing process. But now, the methodology of TRIZ has been expanded to the more non-technological areas to help minimise the limitations of the Six Sigma methodologies.

Integration of I-TRIZ and Six Sigma methodologies generally leads to significantly:

Increased effectiveness of Six Sigma deployments, especially in small and medium business units.

Increased efficiency in terms of reduced life-cycle time and resources used, as well as higher ROI of Six Sigma projects.

Reduced or avoided "expensive" errors in decision making, especially at the early stages of the deployment (i.e. Define or Identify phase).

Reduced Cost of Poor Quality of Six Sigma due to the rework (i.e. repeated and/or redundant measurements, etc.).

Increased Roll Throughput Yield of Six Sigma projects especially at the Improve/Design phase (i.e. percent of Innovative Competitive Solutions/Amount of Collected Ideas).

Approach for the paper

The purpose of the paper is to improvise the six sigma process applied on the Wine making process using the TRIZ principles for the following problem.

The problem faced by the industry is that Dry wines contain substances beneficial to human health; however, they cannot be given to children. The alcohol can be evaporated from the wine by boiling, but the high temperatures destroy the beneficial substances in the wine.

Our approach to improve the process would be applying the 40 principles of TRIZ to the wine making process. The solution for the problem was found in the principles of physics using which used the concepts of pressure which are entirely outside the boundaries of wine making process.

Conclusion

Looking for solutions for problems faced in the wine making industry in other industries helped find the solution to problem faced by the wine makers.

PART I

1.1 What is Six Sigma?

Six-Sigma is a revolutionary business process designed to significantly reduce organizational inefficiencies thereby increasing bottom-line profits. The concept is to eliminate defects that take time and effort to repair, not to mention make customers unhappy. It is a management philosophy that eliminates defects by emphasizing understanding, measuring and improving processes.

It is important to recall that every customer always values consistent and predicable services and/or products with near zero defects. Therefore they experience the variation and not the mean. Mean is their expectation or our target. If we can measure process variations that cause defects i.e. unacceptable deviation from the mean or target, we can work towards systematically managing the variation to eliminate defects. Six Sigma is a methodology focused on creating breakthrough improvements by managing variation and reducing defects in processes across the enterprise.

1.2 How does Six Sigma work?

The driving force behind any Six Sigma project comes from its primary focus - "bringing breakthrough improvements in a systematic manner by managing variation and reducing defects". This requires us to ask tougher questions, raise the bar significantly, and force people to think out of the box and to be innovative. The objective is to stretch, stretch mentally and not physically. To make this journey successful there is a methodology(s) to support Six Sigma implementations.

There are 2 potential scenarios

a) There is already an existing process(s) that is working "reasonably" well and

b) There is no process at all. A bad process is as good as no process.

Scenario (a) focuses on significant process improvements and requires use of DMAIC:

Figure 1: DMAIC Process 1. Define process goals in terms of key critical parameters (i.e. critical to quality or critical to production) on the basis of customer requirements or Voice Of Customer (VOC)

2. Measure the current process performance in context of goals

3. Analyze the current scenario in terms of causes of variations and defects

4. Improve the process by systematically reducing variation and eliminating defects

5. Control future performance of the process

Scenario (b) focuses on process design using Design For Six Sigma (DFSS) approach. DFSS typically requires IDOV:

1. Identify process goals in terms of critical parameters, industry & competitor benchmarks, VOC

2. Design involves enumeration of potential solutions and selection of the best

3. Optimize performance by using advanced statistical modeling and simulation techniques and design refinements

4. Validate that design works in accordance to the process goals

Sometimes a DMAIC project may turn into a DFSS project because the process in question requires complete re-design to bring about the desired degree of improvement. Such a discovery usually occurs during improvement phase of DMAIC.1.3 What is TRIZ?

While there are many widely used design and development approaches such as Quality Function Deployment, these show us what to solve but not always how to solve the technology bottlenecks that arise. One technique, the Reviewed Dendrogram, relies on the experience of designers which may be limited to certain areas of expertise such as chemistry or electronics. Thus, a solution that might be simpler and cheaper using magnetism could be missed. For example, a materials engineer searching for a dampener may limit his search to rubber based materials. A more efficient solution might lie in creating a magnetic field. Since this is outside the experience of the engineer, how could he imagine such a solution? Using TRIZ i.e. Theory of Inventive Problem Solving, he would be able to explore design solutions in fields other than his own.

There are two kinds of problem solutions:

1. Applying from standard solutions

2. Inventive Problem.: with no known solution and may contain contradictory requirementsThe non-existence of a solution leads to what is called psychological inertia, where the solutions being considered are within one's own experience(domain) and do not look at alternative options to develop new concepts.

Figure 2:psychological inertiaExample of psychological inertia

A problem in using artificial diamonds for tool making is the existence of invisible fractures. Traditional diamond cutting methods often resulted in new fractures which did not show up until the diamond was in use. What was needed was a way to split the diamond crystals along their natural fractures without causing additional damage. A method used in food canning to split green peppers and remove the seeds was used. In this process, peppers are placed in a hermetic chamber to which air pressure is increased to 8 atmospheres. The peppers shrink and fracture at the stem. Then the pressure is rapidly dropped causing the peppers to burst at the weakest point and the seed pod to be ejected. A similar technique applied to diamond cutting resulted in the crystals splitting along their natural fracture lines with no additional damage.

1.4 TRIZ tools

TRIZ has a set of general principles (40) that may be used to resolve the contradiction in the system, based on observations collected from the analysis and decomposition of patents. This analysis allows the practitioner to convert, by abstraction, from the specific to the generic and allows the problem solver to take advantage of the fact that elements of the problem in question have already been solved by someone else.

Contradiction theory is the foundation of TRIZ. The abstraction of a generic problem may be carried out by identifying the technical contradiction in th