Advertisement

Reducing the Scrap Generation by Continuous Improvement: A Case Study in the Manufacture of Components for the Automotive Industry

  • J. Pereira
  • F. J. G. Silva
  • J. C. SáEmail author
  • J. A. Bastos
Conference paper
  • 25 Downloads
Part of the Lecture Notes in Networks and Systems book series (LNNS, volume 122)

Abstract

The automotive industry is one of the most demanding sectors of the global market. The response capacity and flexibility of companies represent a key factor for their success. Applying Six Sigma, it was carried out an improvement project aiming at reducing the quantity of scrap on the most critical sector of a automotive components’ manufacturer achieving a better comprehension of the flows, process characteristics and different variables associated to the scrap generation, identifying the equipment responsible for that scrap and its type. Brain- storming sessions were performed, as well as the application of 5 Why’s and 5W2H techniques in order to fulfill the Ishikawa diagrams aiming at understanding possible root-causes for the scrap generation. A definition of the improvement actions has been developed. A reduction of 15% was achieve just in the machine identified as the main generator of scrap in these processes.

Keywords

DMAIC Continuous improvement Six sigma OEE Automotive industry 

References

  1. 1.
    Costa RJS, Silva FJG, Campilho RDSG (2017) A novel concept of agile assembly machine for sets applied in the automotive industry. Int J Adv Manuf Technol 91:4043–4054CrossRefGoogle Scholar
  2. 2.
    Costa MJR, Gouveia RM, Silva FJG, Campilho RDSG (2018) How to solve quality problems by advanced fully-automated manufacturing systems. Int J Adv Manuf Technol 94:3041–3063CrossRefGoogle Scholar
  3. 3.
    Santos J, Gouveia RM, Silva FJG (2017) Designing a new sustainable approach to the change for lightweight materials in structural components used in truck industry. J Clean Prod 164:115–123CrossRefGoogle Scholar
  4. 4.
    Rosa C, Silva FJG, Ferreira LP, Campilho R (2017) SMED methodology: the reduction of setup times for steel wire-ropes assembly-lines in the automotive industry. Procedia Manuf 13:1034–1042CrossRefGoogle Scholar
  5. 5.
    Rosa C, Silva FJG, Ferreira LP (2017) Improving the quality and productivity of steel wire-ropes assembly-lines for the automotive industry. Procedia Manuf 11:1035–1042CrossRefGoogle Scholar
  6. 6.
    Moreira A, Silva FJG, Correia AI, Pereira T, Ferreira LP (2018) Cost reduction and quality improvement in the printing industry. Procedia Manuf 17:623–630CrossRefGoogle Scholar
  7. 7.
    Antoniolli I, Guariente P, Pereira MT, Ferreira LP, Silva FJG (2017) Standardization and optimization of an automotive components production line. Procedia Manuf 13:1120–1127CrossRefGoogle Scholar
  8. 8.
    Neves P, Silva FJG, Ferreira LP, Pereira T, Gouveia A, Pimentel C (2018) Implementing lean tools in the manufacturing process of trimmings products. Procedia Manuf 17:696–704CrossRefGoogle Scholar
  9. 9.
    Silva FJG, Campilho RDSG, Ferreira LP, Pereira MT (2018) Establishing guidelines to improve the high-pressure die casting process of complex aesthetics parts. In: M. Peruzzini et al (eds) Proceedings of the transdisciplinary engineering methods for social innovation of industry 4.0. IOS Press. https://doi.org/10.3233/978-1-61499-898-3-887
  10. 10.
    Pinto H, Silva FJG (2017) Optimisation of die casting process in Zamak alloys. Procedia Manuf 11:517–525CrossRefGoogle Scholar
  11. 11.
    Castro TAM, Silva FJG, Campilho RDSG (2017) Optimising a specific tool for electrical terminals crimping process. Procedia Manuf 11:1438–1447CrossRefGoogle Scholar
  12. 12.
    Costa C, Silva FJG, Gouveia RM, Martinho RP (2018) Development of hydraulic clamping tools for the machining of complex shape mechanical components. Procedia Manuf 17:563–570CrossRefGoogle Scholar
  13. 13.
    Barbosa B, Pereira MT, Silva FJG, Campilho RDSG (2017) Solving quality problems in tyre production preparation process: a practical approach. Procedia Manuf 11:1239–1246CrossRefGoogle Scholar
  14. 14.
    Costa T, Silva FJG, Ferreira LP (2017) Improve the extrusion process in tire production using six sigma methodology. Procedia Manuf 11:1104–1111CrossRefGoogle Scholar

Copyright information

© Springer Nature Switzerland AG 2020

Authors and Affiliations

  • J. Pereira
    • 1
  • F. J. G. Silva
    • 1
  • J. C. Sá
    • 1
    • 2
    Email author
  • J. A. Bastos
    • 1
  1. 1.ISEP—School of EngineeringPolytechnic of PortoPortoPortugal
  2. 2.IPVC—School of Business SciencesPolytechnic Institute of Viana Do CasteloValençaPortugal

Personalised recommendations