IME MS Paper Areeb Mahmood 2020 Root Cause Analysis and Reduction of a Paint Defect using Six Sigma DMAIC Prabhu

In this era of increased demand for automobiles, quality is a major deciding factor when a customer buys any vehicle. Higher quality is directly proportional to having a lower scrap rate and cost of rework. Achieving high-quality standards is a difficult task but statistical techniques make it easy to improve as well as to measure the existing quality levels and Six Sigma is one of these techniques. In this paper, DMAIC Six Sigma methodology is used to reduce a “sand-mark” defect on a painted vehicle in the Tesla Factory. DMAIC combined with concepts of DOE, hypothesis testing, regression modeling, Ishikawa diagram, mistake proofing were used to determine the potential factors affecting this defect. Further analysis was performed to determine the important ones which were curing factors, disk type and polisher type affects this type of defect and to also determine the combination of these factors which provided the best results. On using these techniques the Defect per Unit(hereinafter referred to as DPU) was reduced from 0.66 to 0.26 , as well as defective unit percentage reduced by 10 %. This paper demonstrates how the different steps of this methodology are applied while using various improvement tools and how this can help in achieving improved result.

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Work Title IME MS Paper Areeb Mahmood 2020 Root Cause Analysis and Reduction of a Paint Defect using Six Sigma DMAIC Prabhu
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Penn State
Creators Areeb Mahmood
Version number 1
License All rights reserved
Work Type Research Paper
Publication Date 2020
Deposited November 30, 2020 12:28

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    Description
    • In this era of increased demand for automobiles, quality is a major deciding factor when a customer buys any vehicle. Higher quality is directly proportional to having a lower scrap rate and cost of rework. Achieving high-quality standards is a difficult task but statistical techniques make it easy to improve as well as to measure the existing quality levels and Six Sigma is one of these techniques. In this paper, DMAIC Six Sigma methodology is used to reduce a “sand-mark” defect on a painted vehicle in the Tesla Factory. DMAIC combined with concepts of DOE, hypothesis testing, regression modeling, Ishikawa diagram, mistake proofing were used to determine the potential factors affecting this defect. Further analysis was performed to determine the important ones which were curing factors, disk type and polisher type affects this type of defect and to also determine the combination of these factors which provided the best results. On using these techniques the Defect per Unit(hereinafter referred to as DPU) was reduced from 0.66 to 0.26 , as well as defective unit percentage reduced by 10 %. This paper demonstrates how the different steps of this methodology are applied while using various improvement tools and how this can help in achieving improved result.
    Publication Date
    • 2020
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    • http://www.europeana.eu/portal/rights/rr-r.html
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