Aplicação da metodologia seis sigma para redução dos custos de retrabalho e inspeção para atender a especificação de rosca das conexões de reservatórios de ar

Abstract

The use of Six Sigma DMAIC method, as aid (Sets – Mesuare-Analyse-Increase-Control) for the solution of problems is increasingly common among companies. Thus, the present work aims to reduce rework and inspection costs in the production process of air tanks in a large company of Rio Grande do Sul, Brazil. For this, it was used as a work methodology, the case study due to this methodology to facilitate the application of the method in the day by day of a company. From the beginning of the study, as the basis of DMAIC, the first step was the definition of the problem, with its primary and secondary metrics, and project team. The problem in question was the high spent on rework and inspection in the manufacturing process of air tanks due to non-attendance of the screw in the final specification. Goal to be reach was set to 50% reduction of these costs. After Mesuare phase, due to lack of data that could be analyzed, was foreseen to monitoring of production batches in order to obtain data. After, with the help of the team, Ishikawa diagram of the process was developed aiming the possible causes, which were classified in an array prioritization. On the Analyses stage, the causes listed as priority were investigated, utilizing statistical and graphical methods, in order to establish which factors were significant, being the electrocoat paint process the biggest influencer in the screw specification. With the information in the known process, an action plan was proposed in phase Increase, with deadlines and responsible. It is concluded that, with the implementation of the action plan, the cost reduction target will be achieved. In addition, it was perceived, by the author of this work, the strength and the ability to generate results of Six Sigma methodology.