Applying Six sigma techniques in plastic injection molding industry

This paper presents an approach to implement a six sigma technique to decrease the scrap rate in a plastic injection molding plant. Using a case study of NATPACK Co. a plastic packaging company in Al Obour City, Cairo, Egypt. A Six sigma DMAIC methodology was applied to structure the study and scope the project. DMAIC which stands for define, measure, analyze, improve, control is widely used in many six sigma projects since the 1990s. The proper tools that are suitable for injection molding industry needs were investigated. The primary tools used are SIPOC, MSA, FMEA, P-control charts, hypothesis testing. In this case study we compare the average scrap rate for the ¿before¿ study period with the average scrap rate of the ¿after¿ study period.