Quality improvement in manufacturing industry by using DMAIC approach

Taharim, Nor Najwa (2017) Quality improvement in manufacturing industry by using DMAIC approach. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Industries nowadays are battling in world's competitive market, are attempting to find the best solution aiming to improve the quality of the product, minimize the defect value in the production and reduce the cost. The increasing number of defect on product and rework in production has been affecting the customer’s trust towards the capability of the product production in the company. In this project, DMAIC approach (Define, Measure, Analyse, Improve, and Control) has been used to minimize the defect and analyse the root cause, provide ideas for improve the performance of manpower and reduce the defects in the production of assembly stage faced by an aero composite manufacturing company. The team of Six Sigma was developed to work on the issue related to the major defect faced in the production. Through this project, distinctive quality tools, such as SIPOC, Process Mapping, Pareto Chart, brainstorming, cause and effect diagram, Check Sheet, XY matrix, Quality Function Deployment (QFD), Poka- Yoke, and control plan were used in the different phase in DMAIC methodology. Based on the result, new tool has been designed for improving the performance of workers doing work primer task at EOP. This tool has reduced the cycle time from 37.81 minute per area to 2.57 minute per area. The user feedbacks have given a positive result according to the recommendation of tool design with the rating for insufficient primer issue has improved from 2.83 to 3.00. Hence, DMAIC methodology is an efficient approach for achieving the target of this project.

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