The production of heavy vehicles is a complex process with emphasis on product quality and manufacturing cost. The commonly manufactured vehicles are loaders, haulers, excavators, transporters and other types of trucks. The production of these machines is critical as it involves large, expensive components and safety risks. Also, the cost of the final products is very high compared to road vehicles. Hence, the reliability and quality of the commercial vehicles are the foremost concerns during the production process. This study was conducted in the production system of Caterpillar India Pvt Ltd (CIPL), the global leader in manufacturing construction and mining equipment. The Caterpillar Production System (CPS) is a common order-to-delivery process consisting of three subsystems, namely operational, cultural and management systems. CPS is built on a strong foundation of Six Sigma, a tool for continuous improvement to ensure quality. Six Sigma is a methodology consisting of tools for improving processes and eliminating defects. It is a measure of variability in the final quality of products. It represents the six standard deviations between the mean and the nearest specification limit of the product. The higher the number of process sigma, the fewer the defects. CPS uses fact-based, data-driven Six Sigma to continually manage, improve and create processes through a core methodology called DMAIC (Define, Measure, Analyze, Improve, and Control). This can be implemented through team-based problem-solving events called Rapid Improvement Workshops (RIW). RIW is a week-long event during which a team attempts quick, focused discovery of root causes and implementation of solutions. This paper illustrates the effective use of Rapid Improvement Workshop to reduce defects in the production line. It describes the problem definition, the various tools and techniques used and the Six Sigma approach followed for eradicating those problems. The different elements of the approach are analyzed, demonstrating the impact on the process and its implications.
La produzione di veicoli pesanti è un processo complesso con enfasi sulla qualità del prodotto e sui costi di produzione. I veicoli comunemente prodotti sono caricatori, dumper, escavatori, trasportatori e altri tipi di camion. La produzione di queste macchine è fondamentale in quanto comporta componenti di grandi dimensioni e costosi e rischi per la sicurezza. Inoltre, il costo dei prodotti finali è molto alto rispetto ai veicoli stradali. Quindi, l'affidabilità e la qualità dei veicoli commerciali sono le preoccupazioni principali durante il processo di produzione. Questo studio è stato condotto nel sistema di produzione di Caterpillar India Pvt Ltd (CIPL), leader mondiale nella produzione di attrezzature per l'edilizia e l'estrazione mineraria. Il sistema di produzione Caterpillar (CPS) è un processo di ordine di consegna comune costituito da tre sottosistemi, vale a dire sistemi operativi, culturali e di gestione. CPS è costruito su solide fondamenta di Six Sigma, uno strumento per il miglioramento continuo per garantire la qualità. Six Sigma è una metodologia composta da strumenti per migliorare i processi ed eliminare i difetti. È una misura della variabilità nella qualità finale dei prodotti. Rappresenta le sei deviazioni standard tra la media e il limite di specifica più vicino del prodotto. Maggiore è il numero di sigma di processo, minori sono i difetti. CPS utilizza Six Sigma basato sui fatti e basato sui dati per gestire, migliorare e creare continuamente processi attraverso una metodologia core chiamata DMAIC (Definisci, Misura, Analizza, Migliora e Controlla). Questo può essere implementato attraverso eventi di problem-solving basati sul team chiamati Rapid Improvement Workshops (RIW). RIW è un evento di una settimana durante il quale un team tenta una scoperta rapida e mirata delle cause alla radice e l'implementazione delle soluzioni. Questo documento illustra l'uso efficace del laboratorio di miglioramento rapido per ridurre i difetti nella linea di produzione. Descrive la definizione del problema, i vari strumenti e le tecniche utilizzate e l'approccio Six Sigma seguito per sradicare tali problemi. I diversi elementi dell'approccio sono analizzati, dimostrando l'impatto sul processo e le sue implicazioni.
Implementation of Six Sigma RIW in automotive production system
KANNAN, SURESH;GUNASEKAR, NARENDRAN
2017/2018
Abstract
The production of heavy vehicles is a complex process with emphasis on product quality and manufacturing cost. The commonly manufactured vehicles are loaders, haulers, excavators, transporters and other types of trucks. The production of these machines is critical as it involves large, expensive components and safety risks. Also, the cost of the final products is very high compared to road vehicles. Hence, the reliability and quality of the commercial vehicles are the foremost concerns during the production process. This study was conducted in the production system of Caterpillar India Pvt Ltd (CIPL), the global leader in manufacturing construction and mining equipment. The Caterpillar Production System (CPS) is a common order-to-delivery process consisting of three subsystems, namely operational, cultural and management systems. CPS is built on a strong foundation of Six Sigma, a tool for continuous improvement to ensure quality. Six Sigma is a methodology consisting of tools for improving processes and eliminating defects. It is a measure of variability in the final quality of products. It represents the six standard deviations between the mean and the nearest specification limit of the product. The higher the number of process sigma, the fewer the defects. CPS uses fact-based, data-driven Six Sigma to continually manage, improve and create processes through a core methodology called DMAIC (Define, Measure, Analyze, Improve, and Control). This can be implemented through team-based problem-solving events called Rapid Improvement Workshops (RIW). RIW is a week-long event during which a team attempts quick, focused discovery of root causes and implementation of solutions. This paper illustrates the effective use of Rapid Improvement Workshop to reduce defects in the production line. It describes the problem definition, the various tools and techniques used and the Six Sigma approach followed for eradicating those problems. The different elements of the approach are analyzed, demonstrating the impact on the process and its implications.| File | Dimensione | Formato | |
|---|---|---|---|
|
2018_12_KANNAN_SURESH FINAL.pdf
solo utenti autorizzati dal 09/12/2019
Descrizione: Thesis Report - Kannan Suresh, Gunasekar Narendran
Dimensione
2.14 MB
Formato
Adobe PDF
|
2.14 MB | Adobe PDF | Visualizza/Apri |
I documenti in POLITesi sono protetti da copyright e tutti i diritti sono riservati, salvo diversa indicazione.
https://hdl.handle.net/10589/144110