Quality and its assurance is one of the prime concerns and driver for any service or production company. Achieving desired quality level will ultimately enhance overall customer satisfaction which will result increased sales. This study is done based on real project of initiated by the Production Engineering Department of Indus Motor Company(location). The objective was to reduce the part defects of car during the production process and to improve sigma level using tools of Quality Control by implementing SIX SIGMA DMAIC methodology. Indus Motor Company is a joint venture agreement between House of Habib of Pakistan, Toyota Motor Corporation and Toyota Tsusho Corporation of Japan. Currently the daily production is 240 units per day. Press, Welding, Painting and Assembly operations are carried out at the facility located in Southern part of Pakistan, Bin Qasim, Karachi. DMAIC process is a core component of the Six Sigma methodology. It is used when making improvements to an existing process. It consists of 5 phases namely Define, Measure, Analyze, Improve, and Control. During the first phase, Side skirts and bumpers were chosen after Pareto analysis of the line side defects. Most of the defects in those parts were aesthetic in nature and related to paint. So, the point of focus was Paint shop specifically Bumper booth painting. 8 major defect types were identified which were condensed into 6 main types after Pareto analysis in the second phase. Next phase of the project deals with the analysis of the process for root cause identification. All the defects are addressed individually with respect to their severity and contribution towards cause. Finally, all the recommendations and improvements are documented along with its necessary details of implementation. Practicality and rationality of all the recommendations were focused specifically to achieve the desired quality level.
La qualità e la sua garanzia sono una delle principali preoccupazioni e driver per qualsiasi servizio o azienda di produzione. Raggiungere il livello di qualità desiderato alla fine aumenterà la soddisfazione generale del cliente, il che comporterà un aumento delle vendite. Questo studio è basato sul progetto reale avviato dal Dipartimento di ingegneria della produzione di Indus Motor Company (sede). L'obiettivo era quello di ridurre i difetti delle parti dell'auto durante il processo di produzione e di migliorare il livello di sigma utilizzando gli strumenti del controllo di qualità implementando la metodologia SIX SIGMA DMAIC. La Indus Motor Company è un accordo di joint venture tra la House of Habib del Pakistan, la Toyota Motor Corporation e la Toyota Tsusho Corporation del Giappone. Attualmente la produzione giornaliera è di 240 unità al giorno. Le operazioni di stampa, saldatura, verniciatura e assemblaggio vengono eseguite presso l'impianto situato nella parte meridionale del Pakistan, Bin Qasim, Karachi. Il processo DMAIC è un componente fondamentale della metodologia Six Sigma. Viene utilizzato quando si apportano miglioramenti a un processo esistente. Consiste di 5 fasi: Definisci, Misura, Analizza, Migliora e Controlla. Durante la prima fase, gonne laterali e paraurti sono stati scelti dopo l'analisi Pareto dei difetti del lato linea. La maggior parte dei difetti di quelle parti erano di natura estetica e legati alla pittura. Quindi, il punto focale era Paint shop, in particolare la pittura di stand Bumper. Sono stati identificati 8 tipi principali di difetti che sono stati condensati in 6 tipi principali dopo l'analisi di Pareto nella seconda fase. La fase successiva del progetto riguarda l'analisi del processo per l'identificazione della causa principale. Tutti i difetti sono affrontati individualmente in relazione alla loro gravità e al loro contributo alla causa. Infine, tutte le raccomandazioni e i miglioramenti sono documentati insieme ai dettagli necessari per l'implementazione. Praticità e razionalità di tutte le raccomandazioni sono state focalizzate in modo specifico per raggiungere il livello di qualità desiderato.
Reduction in line side damages using Six Sigma methodologies (detailed analysis on bumper booth painting)
AHMED, MUHAMMAD;FAHEEM, MUHAMMAD
2017/2018
Abstract
Quality and its assurance is one of the prime concerns and driver for any service or production company. Achieving desired quality level will ultimately enhance overall customer satisfaction which will result increased sales. This study is done based on real project of initiated by the Production Engineering Department of Indus Motor Company(location). The objective was to reduce the part defects of car during the production process and to improve sigma level using tools of Quality Control by implementing SIX SIGMA DMAIC methodology. Indus Motor Company is a joint venture agreement between House of Habib of Pakistan, Toyota Motor Corporation and Toyota Tsusho Corporation of Japan. Currently the daily production is 240 units per day. Press, Welding, Painting and Assembly operations are carried out at the facility located in Southern part of Pakistan, Bin Qasim, Karachi. DMAIC process is a core component of the Six Sigma methodology. It is used when making improvements to an existing process. It consists of 5 phases namely Define, Measure, Analyze, Improve, and Control. During the first phase, Side skirts and bumpers were chosen after Pareto analysis of the line side defects. Most of the defects in those parts were aesthetic in nature and related to paint. So, the point of focus was Paint shop specifically Bumper booth painting. 8 major defect types were identified which were condensed into 6 main types after Pareto analysis in the second phase. Next phase of the project deals with the analysis of the process for root cause identification. All the defects are addressed individually with respect to their severity and contribution towards cause. Finally, all the recommendations and improvements are documented along with its necessary details of implementation. Practicality and rationality of all the recommendations were focused specifically to achieve the desired quality level.| File | Dimensione | Formato | |
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2017_12_AHMED.pdf
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Descrizione: Reduction in Line Side Damages Using Six Sigma Methodologies (Detailed Analysis on Bumper Booth Painting)
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https://hdl.handle.net/10589/137145