Quality Improvement In The Manufacturing Industry An Application Case

Tee, Chu Ling (2010) Quality Improvement In The Manufacturing Industry An Application Case. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Quality is one of the key success factors for an organization to survive in the global market. The paper will present the methodology for quality improvement in the automotive part manufacturing industry by utilizing six sigma. The work in this paper focuses on the assembly line of alternator by identifying the the source of quality defects on the alternator. Furthermore, investigation is conducted to study root causes of major quality defect and recommendation solution is proposed to reduce the defect rejection. The methodology was developed to investigate the quality defects that caused by human errors. A model DMAIC of six sigma was employed in the study to construct the problem-solving framework for solving high rejection rate of product quality defects in the case company. The process of DMAIC was involved in the identification of various source quality defects on the product, measurement of current process and system, analysis of the collected data quality defects, improvement of reduction quality defects, and controlling of process to sustain improvement. From the results of implementation, there are three major quality defects, which are omission components, wrong parts assembled and loose tighten, that contributed to rejection for the alternator due to human inadvertent and forgetfulness. After root causes were identified, the solution of poka yoke was suggested to effectively control assembly process as well as detect the omission components in the alternator assembly. The particular strength of this study is providing the six sigma implementation to local company for constructing fundamental quality management system and adopting a problem solving method to handle the quality defect issues in the future. .

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