8Ds method of problem solving within automotive industry: Tools used and comparison with DMAIC

Phanden, Rakesh Kumar; Sheokand, Aaryan; Goyal, Kapil Kumar; Gahlot, Pardeep; Demir, Halil İbrahim

doi:10.1016/j.matpr.2022.05.383

Cited by 7 publications

(6 citation statements)

References 18 publications

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“…The DMAIC framework is used as a guide in improving production processes (Kumar Phanden et al, 2022). The defects data collected is production data in August 2022.…”

Section: Methodsmentioning

confidence: 99%

“…The purpose of this research is to solve the problems in the PCB installation process using a data-based approach to be able to provide gradual improvements using the Define, Measure, Analyze, Improve, Control (DMAIC) principle (Kumar Phanden et al, 2022). The DMAIC framework can be used as a solution to solving quality problems that can be implemented in companies.…”

Section: Introductionmentioning

confidence: 99%

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Implementation of DMAIC for Production Quality Control: Case Study of Power Supply Production in Indonesia

Purwojatmiko,

Ambarwati

2023

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The level of competition in the manufacturing industry is getting tougher, making companies must be able to provide the best service to customers. One of the companies in Indonesia engaged in asset monitoring and ship navigation systems, has a production division that produces power supply products. Based on the analysis that has been carried out at the company that there are problems such as a damaged PCB connector that makes the product categorized as a manufacturing defect. This research aims to be able to find alternative improvements to production processes that have a high defect rate. The Define, Measure, Analyze, Improve, and Control (DMAIC) framework is used as a method to shape the mindset of management and employees to be able to solve these problems. Based on this framework, three causes of the problem were found, namely human factors, materials, and inappropriate methods during the production process. Therefore, appropriate corrective actions are taken, and a control process is carried out by comparing control charts, Defects Per Million Opportunities (DPMO) and sigma levels to determine the impact of changes from the improvements made. Quantitatively, there was an increase in the DPMO value of 39.47% and an increase in the sigma level of 8.64%. This shows that the DMAIC framework can provide the right solutions and preventing the same quality problems from happening again.

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“…The DMAIC framework is used as a guide in improving production processes (Kumar Phanden et al, 2022). The defects data collected is production data in August 2022.…”

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Implementation of DMAIC for Production Quality Control: Case Study of Power Supply Production in Indonesia

Purwojatmiko,

Ambarwati

2023

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“…A key element of ensuring customer satisfaction is the effective handling of customer complaints [3]. Phanden et al (2022) stated that satisfaction is defined by customers expressing their dissatisfaction with unmet expectations and unsatisfied needs verbally or in writing [4].…”

Section: Introductionmentioning

confidence: 99%

“…Problem-solving techniques influence operational efficiencies, reduce the wastage of materials, improve production consistency, increase performance, improve the cycle time in production, and increase financial sources [4]. Currently, production processes in the automotive industry and, especially in the field of automotive components and parts, are highly controlled in terms of output quality, and changes in the requirements of buyers of automotive components and parts are occurring at a faster pace.…”

Section: Introductionmentioning

confidence: 99%

Improving the Quality of Automotive Components through the Effective Management of Complaints in Industry 4.0

et al. 2023

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The fundamental problems with component production in the automotive industry are the low quality of the components, the high number of failures, and the subsequent number of complaints. The quality of automotive components is a prerequisite for automated production in a SMART Factory 4.0 in the context of Industry 4.0. Managing complaints is a critical area in the automotive manufacturing industry. The primary goal of this article is to indicate the significance of a CRM system and the importance of complaints management in automotive manufacturing, which improves the quality of the process of producing components while improving the quality of the inputs—the quality of materials, the quality of the human factor, and the quality of the services provided in connection with the components. (1) A Slovak company was selected as the subject of this research, which focuses on the production of automotive parts. (2) The methods of research focused on using economic analysis and instruments of quality management such as the QRQC method, FMEA method, the Ishikawa diagram, and the Pareto analysis and Lorenz curve. This article presents the results of complaints about automotive components: locksets in vehicles. (3) This research shows the basic cause of the problem: a bent pin after riveting in the process of producing the components. In the frame of this research, we suggested corrective measures to eliminate the actual causes of failure in the production of the components. The RPN index reached a level below the limit of 150 (the critical level of the customers’ requirements) after implementing the corrective measures. The total costs of complaints in this year were calculated to be EUR 13.575 and the costs will be reduced gradually after changes are implemented in the production process. (4) A new complaints information system and a new training center are beneficial for solving problems in the production of automotive components. The implementation of a CRM system and other systems are prerequisites for solving customer complaints.

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“…The PDCA cycle has served as a reference due to its strong relationship with the 8Ds, as it has functioned as an advanced approach to decision-making and problemsolving [40,41].…”

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confidence: 99%

Enhancing Scrap Reduction in Electric Motor Manufacturing for the Automotive Industry: A Case Study Using the PDCA (Plan–Do–Check–Act) Approach

Rangel-Sánchez,

Urbina-González,

Carrera-Escobedo

et al. 2024

Applied Sciences

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The automotive industry is increasingly focused on waste management, elimination, and reduction to achieve sustainability and cost reduction. This focus drives the industry towards resource-efficient operations that minimize environmental impact while exceeding customer expectations. Meeting these demands necessitates the adoption of more efficient production methodologies, such as the PDCA cycle. This work presents a case study that illustrates the application of the PDCA methodology to minimize scrap generation due to process variability in a multinational company that manufactures electric motors for the automotive industry. The aim was to demonstrate how the PDCA methodology can improve quality standards by minimizing scrap generated during the manufacture of electrical armatures. Notably, the organization in this case study set a waste target of 0.7%, which was significantly exceeded. Finally, the implementation of this methodology can deliver significant economic benefits, with a total annual cost reduction of approximately USD 135,000.

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8Ds method of problem solving within automotive industry: Tools used and comparison with DMAIC

Cited by 7 publications

References 18 publications

Implementation of DMAIC for Production Quality Control: Case Study of Power Supply Production in Indonesia

Implementation of DMAIC for Production Quality Control: Case Study of Power Supply Production in Indonesia

Improving the Quality of Automotive Components through the Effective Management of Complaints in Industry 4.0

Enhancing Scrap Reduction in Electric Motor Manufacturing for the Automotive Industry: A Case Study Using the PDCA (Plan–Do–Check–Act) Approach

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