Process Improvement of Brake Lever Production Using DMAIC (+)

Abstract

This work describes a strategy to reduce the cost associated with poor quality, by reducing the parts per million defects by Defining, Measuring, Analyzing, Implementing and Controlling (DMAIC) the production process. The method uses a combination of principles of Six Sigma applications, Lean Manufacturing and Shanin Strategy. The process has been used in analyzing the manufacturing lines of a brake lever at a Connecticut automotive components manufacturing company for reducing the cost associated with the production of nonconforming parts. The analysis was carried out with the help of the data collected on nonconformance parts and the application of phase change rules from DMAIC (+). Data analysis was carried out on statistical process control softwares, MINITAB and SPC XL 2000. Although, the problem of tight bushing existed on only one line of the brake lever assembly, this problem solving approach has solved the tight bushing problems on all assembly and alternates lines in a time- and cost-effective way.

Quality Assurance through Process Improvement - A Concise Review

“…Sahey et al [25] once again brought the DMAIC approach into use for analyzing the manufacturing lines of a brake lever manufacturing company at Connecticut. Six sigma DMAIC methodology is combined with Lean production techniques [42] for realizing process improvements in brass extrusion and drawing production lines.…”

“…The applications of manufacturing process capability improvement studies covers wide areas namely, engine manufacturing process [11,12], crane hook manufacturing process [20], plasma machining [21], CNC turning process [22], blow moulding process [23], polyjet printing [24], brake lever manufacturing [25] aircraft turbine engine blade manufacturing [26], photolithography process control in wafer fabrication [27], manufacture and process capability evaluation of square bumps [28], golf club-shaft manufacture in leisure sport industries [29], tool condition monitoring for grinding wheel in IC manufacturing of silicon wafer [30] and LED assembly in electronics industry [31]. All the works cited depict the process improvement procedure and fosters the fact that any noticeable permanent improvement is possible only through inprocess control and not through end inspection.…”

Process capability improvement through DMAIC for aluminum alloy wheel machining

“…The DMAIC approach was used for standardizing the process parameters involved in the manufacture of optical lens with good surface contour precision in the injection-molding process by Lo et al (2009). DMAIC approach is followed in varied platforms such as for improving the process parameters and capability of solder printing process, to analyze the manufacturing lines of a brake lever at an automotive components manufacturing company, to improve the fracture resistance of TFT-LCDs and improve the process capability levels of connecting rod and crankshaft manufacturing cells and minimizing variations in food processing industry (Li et al 2008;Chen et al 2009;Sahay et al 2011;Su et al 2012;Rao 2013, 2014;Desai et al 2015).…”

Process capability improvement of an engine connecting rod machining process

“…Gentili et al (2006) applied the DMAIC process to a mechanical manufacturing process line, which manufactures both professional and simple kitchen knives. Sahay et al (2011) once again brought the DMAIC approach into use to analyze the manufacturing lines of a brake lever at a Connecticut automotive component manufacturing company. Singh (2011) investigated the process capability of polyjet printing for plastic components.…”