Defect Reduction in Helical Gearbox Assembly

Abstract

To achieve and maintain world class manufacturing system, Industries are con- tinuously striving to increase the quality of product they manufacture. In current competitive market there must be best quality product which the customer receives. To improve the quality of product, first of all industry has to eliminate the losses which affects the quality of product. In this project, investigation is carried out in Helical gearbox manufacturing unit to increase the FPY(First pass yield) by eliminating non- conformities like Noise, Leakage, Vibration, High Temperature etc. taking place in production of it. Quality control tools like pareto chart, cause and effect(fishbone) diagram are used to analyze the target area and root cause of non-conformities in the system. Quality Control tools like Why-Why Analysis, OPL(One Point Lesson), 3M(Man, Material, Method), 6W2H(What, Why, Who, When, Where, Whom, How and How much), Kaizen, Pokayoke are used to improve the quality. Elimination of non-conformities in product leads to high quality at low cost. By implementing the quality control tools and revising the 3M Condition using 6W2H action plan, the helical gearbox assembly has significantly reduced the PPM(parts per million) of non-conformities. The PPM level has decreased to 25%-30% compared to the last F.Y..