15-10-2014, 10:01 AM
Abstracts: Productivity determines an organization's growth.The aim of this paper is to study the implementation of engineering tools in a manufacturing moulding machine company. Observations at the production line were made to identify problem occurs in the production line. Then, by using cause and effect diagram, the root cause of the problem was identified and solutions to overcome the problem were proposed. Methods used to improve productivity includes Work Study, Method Study & others are Six Sigma, Lean Manufacturing, 5S Principle etc.Work Study is a generic term for those techniques, particularly method study and work measurement, which are used in the examination of human work in all its contexts, and which lead systematically to the investigation of all the factors which affect the efficiency and economy of the situation being reviewed, in order to effect improvement. Six Sigma is one of the popular methodologies used by the companies to improve the quality and productivity. It uses a detailed analysis of the process to determine the causes of the problem and proposes a successful improvement. Various approaches are adopted while following Six Sigma methodologies and one of them is DMAIC. It consists of phases, namely, Define, Measure, Analyse, Improve, and Control. The successful implementation of DMAIC and FTA is discussed in this paper. In this study, the major problem was of continuous rework up to 16%, which was leading to wastage of man hours and labor cost. Initially, fault tree analysis (FTA) was used to detect the key process input variables (KPIVs) affecting the output. Multivariable regression analysis was performed to know the possible relationship between the KPIVs and the output. The DMAIC methodology was successfully implemented to reduce the rework from 16% bores per month to 2.20% bores per month. The other problem of nonuniform step bores was also reduced significantly.The results indicated that application of technology is the best for improvement of productivity.