IMPROVING COMPRESSED AIR SYSTEM EFFICIENCY AND RELIABILITY WITH SIX SIGMA DMAIC

The six-sigma methodology has been adapted by industry as a business management tool to improve operational capabilities and reduce defects in any process (Mittal et al., 2023). This study aims to present a case study on the implementation of the Six Sigma DMAIC methodology, targeting a 50% reduction in the usage of rental and portable air compressors at a facility. Approximately $824,000.00 per year was spent on compressed air and a good portion of that was wasted on running it inefficiently. Also, the air quality (i.e., oil and water) and equipment reliability impacts the operation of the facility. There was $274,000 spent on portable and rental compressors to keep the plant operational. After implementing some of the Six-Sigma project findings the facility was able to assume an approximate 50% decrease in portable and rental compressor usage, which would yield up to $164,000 per year in cost savings.