Process Improvement in Hydraulic Component Manufacturing Industry using Lean and Six Sigma Concept

Abstract

Most of the manufacturing industry are putting afforts towards the lean manufacturing system to eliminate different types of waste and to achieve operation excellence. Hydraulic components manufacturing company in India is also focusing reduce waste by applying lean principal. The objective of this project is to identify the waste and to reduce waste by using the various lean manufacturing tools like, Value Stream Mapping and Kanban system. Also this project discusses how to improve On Time Delivery performance and to reduce total throughput time in power pack product segment in Bosch Rexroth (I) Ltd. DMAIC methodologies are used for problem solving. Different tools like Pareto chart, Fishbone diagram, and Priority Matrix are used to find root cause On Time Delivery.

Design of Experiment is carried out on Band Saw machine which is bottleneck machine for cutting of cylinder tube. Full factorial method is used for Design Of Experiments (DOE). Main objective of this project is to reduce the cycle time in cylinder cutting operation maintaining the ovality specification. Minitab 16 software is used for Design Of Experiments. ANOVA analysis and regression analysis are carried out to find the significant effect and to develop the empirical model. Optimum parameters are selected from model and suggestion is given to reduce cycle time.