Defect Analysis and Implementation of DMAIC Methodology for Defect Reduction in Tyre Manufacturing

Abstract

 For the development of automobile sector the manufacturing of automobile tyres has become an essential activity.As various parameters are there in manufacturing of automobile tyre, these industries are suffering from number of defects. This paper discusses the productivity and quality improvement in a production sectors by analysis of defects. In this paper DMAIC (Define Measure, Analyze, Improve and Control) six sigma is implemented as an methodology in tyre production plant. Taguchi methodology is used for design of experiments (DOE). DOE helps to investigate the effects of variousinputsand output parameters. It gives the relationship between these two.With addition to DOE, taguchioptimizationis done. In taguchi optimization initially orthogonal array finalized with their levels for process parameters. The signal to noise ratio calculated followed by Analysis of Variance (ANOVA). The two significant parameters such as cleaning frequency and tread identification painting system are used to optimize and reduce the rejections due to various tyre defects. The quality control tools like histogram, 20-80 analysis and cause and effect diagram are used to find the defects in tyres. Taguchi analysis gives reduction in no. of defectives when optimum values of parameters are selected. This approach results in significant financial impact on company quality expenses.