Quality improvement in manufacturing industry using Six Sigma methodologies

Ng, Teck Ming (2018) Quality improvement in manufacturing industry using Six Sigma methodologies. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

The aim of this project is to apply six sigma DMAIC methodology in a company to perform quality improvement. The selected company is a car parts manufacturing company. One of the problem faced by the company was Customer Complaints. Therefore, there were three objectives in this project which were to identify the car parts with problem that has the highest number of customer complaints, analyse the root cause of the problem with highest number of customer complaints and to improve and maintain the product quality. To achieve these objectives, Define-Measure-Analyse-Improve-Control (DMAIC) methodology that consists of five phases was used and tools and techniques like pareto chart, control chart, design of experiment, statistical control plan and others were applied in each phase. Refer to the first objective, the main customer complaint was about the adjustment problem from rear-view mirror, customer complaint that it was difficult to adjust the mirror. So, the force to adjust the rear-view mirror must be reduced to achieve customer satisfaction. Analysis has been made on several factors like Material, Method, Machine and Design. The result showed that only Material and Design gives significant effect. Besides, through DOE analysis, among all the options, Material-2 and Design-2 give the best effect that reduce force required to adjust the mirror. The movement force has been reduced from 17N to 13N by incorporating Material-2 and Design-2. Verification of improvement is made to show the significant improvement and tools like SPC, Quality Control Plan and Quality Assurance Program are used to maintain the situation.

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