Use of six sigma in productivity improvement and cycle time reduction in piping installation during vessel construction

Six Sigma (6σ) is a set of techniques and tools for process improvement. It seeks to improve the quality of the output from a process by identifying and removing the causes of defects and minimizing variability in manufacturing or the process. Some have found the Six Sigma methodology an excellent way to improve their processes as it uses statistical tools to measure processes in terms of defects and variation, transforming them into opportunities for business growth. The project would aim to examine the established piping installation process of a vessel construction, analyse the relevant data to reduce the variability and reduce the cycle time by reducing the rework. It would aim to focus on the existing quality process, analyse the data of acceptance of installed pipes as per QAP, use five established steps of six sigma to provide the requisite control measure for improving the productivity and reducing the cycle time in a vessel construction project. Consistency in achieving planned targets during vessel construction project requires timely availability of Inspection cleared pipes/spools for subsequent processes of Flushing, Leak test & Final Inspection before connecting them, with live engineering systems. The project would also measure the initial sigma level of the existing process and aim to conclude by providing recommended ways of reducing the rejection during quality inspection using established six sigma processes. This project would eventually aim to improve the production process and reduce the cycle time of the entire piping installation process.