1M. Sc. [Engg.] Student, Mechanical and Manufacturing Engineering, MSRSAS, Bangalore, 560 058
2Asst. Professor, Mechanical and Manufacturing Engineering, MSRSAS, Bangalore, 560 058
3Manager-QA, Sanmina-SCI, Chennai
In today's buyer's market; quality based competition is intensifying and enforces any manufacturing industry to produce better quality products with least cost. Quality with least cost is only possible by reducing the rejection rate especially at downstream customer. The study concentrates on the reduction of customer claimed scrap as it is capable of reducing the product profit and also the future business.
Quality is nothing but satisfying the customer needs and expectations on a continuous basis. The scope of this study is (1) Well designed products with functional perfection, (2) Meeting or exceeding customer expectation, (3) Excellence in service and (4) absolute empathy with customer. DMAIC methodology is used for this project, as it serves as a guideline for successfully identifying root cause of the selected problem and for understanding, implementing and evaluating solution/s.
The study brought more than 88% reduction of scrap cost within six months of work. The study brought many tangible and intangible benefits including increased future business. It is concluded from the study that the actual quality is lying with manufacturing process and any complicated problem can be solved by systematic application of DMAIC approach.
Six Sigma, Scrap Reduction, DMAIC, Communication Failure
