DMAIC approach to reduce total duration of prototyping process

Tan, Lee Ping (2016) DMAIC approach to reduce total duration of prototyping process. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

In today’s competitive world, many manufacturing companies focus on the innovative product. Prototype played an important role for innovative product because prototype helps the company to test the functionality and stability of a product. The popularity of the product on the market also can be done by using prototype to determine the customer interest on the product. Once the product received good feedback from the market, the product will enter the mass production phase. This project is conducted at research and development department of a vacuum cleaner company. The purpose of this project is to reduce the total duration of prototyping process by using DMAIC approach. In Define phase, the problems faced by the company were highlighted. The objectives and the scope were determined. A process mapping showed the processes involved in the prototyping process. Next, the data were collected in the Measure phase after the type of data measurement was determined. The data were used to set the benchmark for the current total duration of prototyping process. During Analyze phase, the cause and effect diagram, failure mode and effect analysis, and Pareto chart were used to determine the major causes of the problem. Once the major causes were identified, a solution plan was proposed in Improve phase. A brainstorming workshop process optimization model was used to develop the solution plan. All the processes involved in prototyping process were overhauled and calibrate so that the processes are cleansed and the roles and responsibilities are justified. The solutions were then conducted a pilot run. The data of pilot run were collected. The results showed overall improvement in the prototyping process in Control phase. The significance of this project is that the total duration of prototyping process reduced from 12.4 weeks to 10.4 weeks, which is a 16 percent reduction of the total duration.

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