Reduction of balloon defects in stripping process using DMAIC approach : a case study

Leong, Chee Weng (2017) Reduction of balloon defects in stripping process using DMAIC approach : a case study. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

	Text (24 Pages) Reduction Of Balloon Defects In Stripping Process Using DMAIC Approach - A Case Study - Leong Chee Weng - 24 pages.pdf - Submitted Version Download (901kB)
	Text (Full Text) Reduction of balloon defects in stripping process using DMAIC approach - a case study.pdf - Submitted Version Restricted to Repository staff only Download (2MB)

Abstract

Six Sigma is a well-structured and systematic quality improvement methodology that allowed us to break down the problem and carry out statistical analysis on that problem. The main idea of this project is to implement Six Sigma methodology in the stripping process to solve the quality issues in the stripping process of a case study balloon manufacturing company. The company has been facing a serious product defects problem since it was established. There are many reasons why this issue is still happening. Firstly, the company did not have a proper methodology to deal with defects. Then, the engineer did not realise the how severe is the impact brought by the defects to the company. Next, the operators at stripping process were not capable of dealing with the defects. Besides that, the company also did not have any data to study the defect. The major defect in stripping process was Inverted Neck. Hence, by following the DMAIC methodology, the root cause of the defect was identified and solution to reduce the defect was provided. Various statistical tools were used such as Analysis of Variance (ANOVA), Design of Experiment (DOE), control chart and Cause-and-Effect Diagram. Use of ANOVA and DOE has determined the significant parameter in stripping process that contributed to the defect as well as their optimum values needed to minimize the defect. As a result, the main defect Inverted Neck that was 9.37% at first has been reduced to 3.57% after implementing Six Sigma DMAIC. An estimation of RM21060 can be saved annually after the improvement. The objectives of this project have been achieved. For further optimization, the company should study all the parameters such as temperature and latex compound. Defect handling training should be given to improve the efficiency of Six Sigma project while DOE must continue to be used in order to find the best solution.

Actions (login required)

View Item