The study provides a problem-solving framework that was found effective in implementing a long-term corrective action in an assembly production line.
Sanjeev P. Sahni, Principal Director, Jindal Institute of Behavioural Sciences (JIBS), O. P. Jindal Global University, Sonipat, Haryana, India.
Mithun Sharma, O.P. Jindal Global University, Sonipat, Haryana, India.
Shilpi Sharma, Assistant Professor, Jindal Global Law School, O.P. Jindal Global University, Sonipat, Haryana, India.
The current research study aimed to explore the utility of selected problem-solving tools and techniques in root-cause analysis to demonstrate their practical application.
An experimental research design adopting a positivist empirical approach with a deductive strategy was followed to assess the effectiveness of a combined (8D & Six Sigma) problem-solving approach in reducing a high defects rate of a mixer shower assembly line.
A novel application of the 8D framework in combination with Six Sigma and other analytical tools was found highly effective in reducing the reject rate from 11.84% to 0.11%. Successful identification of the root cause led to the implementation of permanent corrective action ensuring a long-term stable assembly process.
The research study provided a problem-solving framework that was found effective in resolving a complex problem and implementing long-term corrective action in an assembly production line.
However, this framework can be used in other industries. The research study provides a solution to a high number of leak rejects in a sub-assembly where “O-seals” are used between mating parts. It also provides analytical tools that were found highly effective during the problem-solving process.
Published in: Engineering Management in Production and Services
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