22-10-2012, 01:44 PM
SCRAP REDUCTION MODEL: BY COMBINATION OF DMAIC AND DESIGN OF EXPERIMENTS
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ABSTRACT
This project deals with the experimentation which took place at a cable manufacturing
company. The thesis describes and summarizes the various strategies and techniques that
has been applied and practiced for scrap reduction. DMAIC and Six Sigma Technology has
been proven very help full in order to reduce scrap to a major extent. DMAIC help to identify
areas in process where extra expense exist, identify the biggest impact factor related
production expenses, introduce appropriate measurement system, optimize process and
reduce production cost and time. Many issues were detected by the production, such as a
lack of a unified procedure for documenting scrap, as well as cable manufacturing concerns
suggested by new and experienced operators. Another concern was how best to focus on
insulated wire scraps, the reason for scraps and how to correct such things and prevention.
The research task of accurately measuring the scrap by improving scrap logistic proved to be
very successful in order to measure scrap accurately. A statistical approach has been taken to
find the factors affecting the scrap.
The results indicate a precise way for scrap reduction. The results starts from the plant level
scrap, in comparison with the scrap in previous months in this year.
Background of Company
Coleman Cable, Inc. is a leading manufacturer and innovator of electrical and electronic wire
and cable products for the security, sound, telecommunications, electrical construction, for the
retail, commercial, industrial, irrigation, HVAC and automotive markets. It provides one of the
most extensive and diverse lines of electrical, electronic and assembled wire and cable
products in the industry [1]. Examples of the products include flexible cables designed for
aircraft boarding bridges, power and control cables for wind turbines, high performance military
cables for harsh environments, submersible cables for marinas and fountains, lead wire for
panel builders, and power cable for sports lighting systems. Figure 1 describes three major
application areas of wire and cables produced by Coleman Cable, Inc.