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Using DMAIC Six Sigma to systematically improve shopfloor production quality and costs

机译：使用DMAIC六西格码（Six Sigma）系统地提高车间生产质量和成本

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摘要

Purpose - This study sets out to highlight how a leading manufacturer of tooling, with its continuous improvement drive, has leveraged DMAIC Six Sigma potential to realize cost savings and improved quality on their shopfloor. The study examines one of the shopfloor chronic quality issues which deals with finding a way to reduce the amount of warp incurred in Amada A-Station punches during the heat-treat process. Design/methodology//approach - The goals of this specific study were achieved by utilizing Six Sigma tools such as "brainstorming, process mapping, fish-bone diagrams, histograms, and control charts". Findings - The analysis resulted in a number of findings and recommendations. A major contributor to the warp was the method used to fix the parts. It was found that, by using a new fixture to hang the parts, the amount of warp could be greatly reduced. The major recommendation was that the new heat-treat fixture design be implemented as soon as a reliable fixture design has been proven. The value of implementing this new fixture design equates to roughly S10,000 per year in savings, which is due to the elimination of a secondary grinding operation and elimination of scrap parts. The company expects millions of dollars in annual savings as DMAIC Six Sigma process is rolled out to areas on the shopfloor. Originality/value - The case study shows DMAIC Six Sigma process is an effective and novel approach for the machining and fabrication industries to improve the quality of their processes and products and profitability through driving down manufacturing costs.
机译：目的-这项研究着眼于强调领先的工具制造商及其不断改进的驱动力，如何利用DMAIC六西格码的潜力来实现成本节省和提高车间质量。该研究调查了车间的长期质量问题之一，该问题涉及寻找一种方法来减少热处理过程中Amada A-Station冲头产生的翘曲量。设计/方法/方法-通过使用六西格码工具来实现此特定研究的目标，例如“头脑风暴，过程映射，鱼骨图，直方图和控制图”。调查结果-分析得出了许多调查结果和建议。翘曲的主要因素是用于固定零件的方法。已经发现，通过使用新的夹具悬挂部件，可以大大减少翘曲量。主要建议是，一旦可靠的夹具设计得到证实，便应立即实施新的热处理夹具设计。实施这种新型夹具设计的价值每年大约可节省S10,000，这是由于消除了二次磨削操作并消除了废品零件。该公司预计，随着DMAIC 6 Sigma工艺在车间区域的推广，每年将节省数百万美元。独创性/价值-案例研究表明，DMAIC六西格玛工艺是一种有效且新颖的方法，适用于机械加工和制造行业，可通过降低制造成本来提高其工艺和产品的质量以及盈利能力。

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