Improvement in First Pass Yield of Helical Gearbox Assembly Using Six Sigma Approach

Abstract

To achieve and sustain world class production system, Industries are continuously aiming to optimize the quality of product they manufacture. In current cutthroat market there must be finest quality product which the customer receives. To optimize the quality of product, principally we have to eliminate the losses which make influence on quality of product. In this project, analysis is carried out in Helical gearbox manufacturing assembly unit to maximize the FPY (First pass yield) by eliminating non-conformities like Leakage, Noise, Vibration, High Temperature, etc. taking place in production of it. Quality Control tools like Pareto charts, Cause and Effect (Fishbone) diagrams are used to analyze the target area and root cause of non-conformities in the system. Quality Control tools like Kaizen, Why-Why Analysis, 4M (Man, Material, Method, Machine), 6W2H (What, Why, Who, When, Where, Whom, How and How much) Action Plan, Pokayoke are used to optimize the quality. Elimination of non-conformities in manufacturing of Gearboxes helps to increase FPY and leads to excellence quality at low cost. By implementing the quality control tools and revising the 4M Condition using 6W2H action plan, the helical gearbox assembly has significantly reduced the PPM (parts per million) of nonconformities. Because of this FPY and Sigma level of helical gearbox assembly is increased compared to last year FPY data.