Six Sigma Application in Ketchup Industry for Damaged Glass Bottles: A Case Study

The aim of this paper is to examine the problem of loss incurred due to damage of glass bottles in the tomato sauce/ketchup industry which not only results in depreciating economy to the manufacturer but also degrades the reputation of a company and degrades its image. This paper uses the DMAIC methodology which is a part of Six Sigma for evaluating the problem. The identification of the root causes was done using Kaoru Ishikawa Diagram (Fish Bone Diagram). The weight of individual root cause was calculated using Analytical Hierarchy Process (AHP). Pareto Chart was established to figure out the root causes of the greatest consequence, which were having a very significant impact on the deliverables. Subsequently, brainstorming was done with the experts of this field including the department of Quality Control and logistics was organized which facilitated in figuring out the solutions by reviewing the process map. This paper has been the first attempt to find and review the root causes of the problem of Glass Bottles damage in this particular industry and suggest solutions so that there is a decline in the quantity of damages using DMAIC approach given under Six Sigma methodology