To Implement “Lean Six Sigma” Concept in Automobile Manufacturing  

Oleh:

Kumar, K. ; Kumar, Parveen ; Rao, I. V. ; Purushothaman, S. ; Rawat, J.S.

Jenis: Article from Proceeding
Dalam koleksi: 12th ANQ Congress in Singapore, 5-8 Agustus 2014, page 1-11.
Topik: Lean Six Sigma; Customer Satisfaction; Statistical Analysis; Factors; Design of Experiments
Fulltext: PS-2.8-P0327.pdf (813.27KB)

Isi artikel

Lean Six Sigma has emerged as an important area of research in Indian context. The requirement of Lean Six Sigma has increased due to defects in products (semi-finished and finished) and subsequent increase in cost. In this context, this study is an attempt to develop a practical implementation of Six Sigma Methodology and to explain practical use of graphical and statistical tools for problem solving. The Lean Six Sigma DMAIC (Define-Measure-Analyze-Improve-Control) methodology is used to grab this problem. Most painful problem (rubber shot and Crack) in rubber injection machine was selected and rejection data (current and historical) was collected for analyze the problem. After problem identification the target setting has done. Detailed understanding of problem was done by the different methods like Input Output sheet, cause and effect diagram and funneling was done with the help of Cause & Effect matrix and PFMEA. With the help of various graphical tools like Pareto, Box plot, interval plot, main effect plot & statistical tools like Binary Logistics Regression the relationship of input vs output was checked to identify the actual root cause for the problem. So process parameters platen temperature, injection pressure, clamping pressure and operator were optimized and standardized with other parameters with the help of Design of Experiment. By controlling these factors the overall rejection reduced from 3.4% to 0.64%, that is leading 80% improvement in cost saving. Control charts are established in process and training to all concerned employees is provided to ensure the effective implementation of changes

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