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Six Sigma Shaft Grinding Optimization

The document summarizes a Six Sigma project conducted to reduce variation in the grinding process at a manufacturing plant. The project team identified runout of the shaft as a critical to quality characteristic. Through measurement data analysis and a cause-effect diagram, improper feed rate was identified as the root cause. The validation plan proposed experiments to validate the root cause and test solutions. Comparisons before and after showed reductions in defects per million opportunities (DPMO) and increases in first pass yield and process monitoring was implemented. The document concludes with lessons learned around accurate data collection, change management, and reducing quality costs.

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MUHAMMAD ASJAD AAMIR AAMIR AMIN
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201 views20 pages

Six Sigma Shaft Grinding Optimization

The document summarizes a Six Sigma project conducted to reduce variation in the grinding process at a manufacturing plant. The project team identified runout of the shaft as a critical to quality characteristic. Through measurement data analysis and a cause-effect diagram, improper feed rate was identified as the root cause. The validation plan proposed experiments to validate the root cause and test solutions. Comparisons before and after showed reductions in defects per million opportunities (DPMO) and increases in first pass yield and process monitoring was implemented. The document concludes with lessons learned around accurate data collection, change management, and reducing quality costs.

Uploaded by

MUHAMMAD ASJAD AAMIR AAMIR AMIN
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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By:

M. Asjad Aamir (2016-ME-10)


Umar Imtiaz (2016-ME-11)
Naeemullah (2016-ME-12)
Six Sigma

Business
Strategy

Reduce Reduce Process Decrease


Production Cost Variation nonconformities
Define

Control Measure

Improve Analyze
Problem Identification
Process Capability was reported 0.29
Controlled by different
parameters of grinding
process

Runout of shaft
identified as CTQ SPC Committee
characteristic
Team

Engineering unit
Project Charter

Leader
Composition of
(Engineering
team
Manager)

Production and
2 Quality Control 3 Production Line
Quality Assurance
Engineers operators
Supervisors

Project Scheduling, scope,


resources, anticipated results
Grinding

Supplier Input Process Output Customer

SIPOC Drawing and product


specifications Checking
Lubricant
Equipment Defects
Electricity
Setting process
parameters
Machine operator
Mega Motors
Machine
Features SAIPA
accessories Start the
Work instructions machine
Quality Control
Documents of
equipment In process the first off
Quality control controls
plan
Dial Bore
Gauge

Runout of shaft should be less than


0.0015mm
Validation of
Examine Data entry
data accuracy
Two Gathering of
Selection of measurement data(60
suitable gauge experts, Ten observations
components over 8 weeks)

20% variation Examination of


Measurement in data on
of Data measurement minitab
system software
Cause Effect Diagram
Validation Plan

Causes Validation
Low precision of micrometer Calibration

Low precision of operator Evaluation

Not optimum machine parameters Experimental Design methods

Improper Feed and feed rate Process audit

Machine adjustment not done Standard operating procedures


properly
Low machine precision R&D

Using live or dead center Experimental Design methods


Validation Plan

Validate root cause Solution


Improper feed and speed rate Adjustment procedure implementation

CP machine adjustment not done properly Shaft adjustment with MAE machine

Drive changing This is introduced as a parameter to be


checked in machine preventive maintenance
checklist
Using dead center or live center Introduced dead center through DOE

Stopping & restart of machine for various Introduced operator before restarting of the
machine
Validation Plan
Validation Plan
Validation Plan

identifying improvement
stakeholders

communicating the
proposed solution and
benefits

MANAGE CHANGE learning organization

training and development


of knowledgeable staff

celebrating the success


Comparisons of results before and after the project

Before After

DPMO 725747 66807

First Yield % 27.4 93.3


Grinding process monitoring
 Defects reduction
 Reference paper for other industries
 Cost saving
 Increase in products
 Quality and customer Satisfaction
Root cause of
problem

Lesson
Accurate learned Reduce
data
collection in quality cost
project

Use of
change
management
approach
Any
Question?
20

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