Abstract
Abstract : This study is based on the clay brick products manufactured by rural Small to Medium Enterprises (SMEs). Customers complain that clay bricks that are purchased from SMEs, break during the process of building houses. This research aims at investigating the fundamental sources for deficiencies in SMEs clay bricks. The solutions to the challenges are facilitated via the application of the Six Sigma`s benchmarks. The benchmarks are most often described in research as Define; Measure; Analyse; Improve; and Control (DMAIC) protocols. On completion of a detailed observation of the current processes implemented by the SME under investigation, a SIPOC illustration is designed. SIPOC is often referred as suppliers, inputs, process, outputs and customers diagram. During the measuring and improvement phase clays are respectively processed at the laboratory to form test briquette samples. The strength of the formed test briquettes is measured through the modulus of rupture (MOR). The Minitab 18 software is used to calculate the process capability and Anderson- Darling test of MOR results. The laboratory results of the original clay sample are analysed through the Ishikawa and Pareto diagrams. Lessons learnt are documented for future references during the control phase. The Pareto diagram illustrates that low plasticity in the SME original clay sample must be improved. Plasticity of the original clay sample is improved through addition of bentonite clay. The null hypothesis is rejected before improvement and accepted after improvement. The defect rate is improved from 2.69% to 0.30%. The Process capability index is also improved from inadequate (0.68) to capable (1.03). The DMAIC protocols is found to be optimally significant related to reducing defects in SME clay bricks, since the sigma level is improved from 3.43 to 4.24. There are opportunities for future research such as improving the process capability index of SME products, developing clay mining equipment and procedures, environment studies, marketing and a funding model should be developed.
M.Phil. (Engineering Management)