Quality Enhancement In Fan Cowl Assembly In An Aero Composite Manufacturing Company Using DMAIC Approach

• Main Author: Saari, Saadatunur
• Format: Thesis
• Language: English; English
• Published: 2016
• Subjects: T Technology (General); TS Manufactures
• Online Access: http://eprints.utem.edu.my/id/eprint/20779/1/Quality%20Enhancement%20In%20Fan%20Cowl%20Assembly%20In%20An%20Aero%20Composite%20Manufacturing%20Company%20Using%20DMAIC%20Approach%20-%20Saadatunur%20Saari%20-%2024%20Pages.pdf; http://eprints.utem.edu.my/id/eprint/20779/2/Quality%20Enhancement%20In%20Fan%20Cowl%20Assembly%20In%20An%20Aero%20Composite%20Manufacturing%20Company%20Using%20DMAIC%20Approach%20-%20Saadatunur%20Saari.pdf; http://eprints.utem.edu.my/id/eprint/20779/; https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=104908

Too often quality issues were taken lightly in the production. The organisation put more focus on pinpointing and counting the defect rather than improving the management performance. Hence increasing the number of rework in the production that will eventually increase time of production and cost. This situation will affect the customer’s trust towards the capability of the production. Facing quality issues in their production, an aero composite manufacturing company realise in increasing their competitive advantage, there are needs for their company to improve their operations through producing “right first time” quality product. Defects minimisation is the prerequisite to the quality improvement. Hence, this study presents the defects minimisation rate by introducing and implementing DMAIC methodology of Six Sigma into a fan cowl assembly of a selected aero composite manufacturing company. This improvement method from Six Sigma is a customer driven improvement approach that originally started in manufacturing industry. This systematic approach towards defects minimisation have been effectively utilised in many improvement process through five phases of DMAIC methodology named Define, Measure, Analyse, Improve and Control. Through this study, a Six Sigma team was developed to work on this issue. In this study, Pareto chart was used to identify the top occurring defects. Finding shows that quality issues related to sealant has become a great contribution to a high DPU number. Hence, the team has worked together to identify the major cause that led to the defects. Tools and techniques such as brainstorming, cause and effect analysis and FMEA were used to identify the probable causes and the potential root causes. Through data collection and several discussion, the team agreed that, being a manual assembly production would results to higher manual variability that will eventually led to human error. Different technique were used by the worker depending on their experience and also human factor affecting them while working. It was found that, by addressing error and incorporating them into control plan could greatly reduce the human error. Hence, the proper implementation of SOP and control plan were implemented in this study as the control measure in sustaining the improvement in the process. The results shows that this implementation help the workers to be more focus in doing their job. Besides, the record keeping system that has been documented will later greatly contribute in data collection in aiding another continuous improvement process.