Quality Improvement Research For Bicycle DC Dynamo Of T Company

Nowadays,bicycle and bicycle components manufacturing company have to confront the saturation of middle & low end market,moreover,they suffering downturn any more during the development bottleneck of production capacity surplus but without advent of revolutionary innovation products.It is a quite important challenging project for every enterprise how to survive and develop in fierce competitions.T company,a traditional bicycle components manufacturer seized the chance of “sharing economy” in 2016,entered shared-bikes market through cooperate with shared bike enterprises,so made the sales amount grew into a new growth pole.meanwhile,T company came to realize the shortage of its business,like product variety single /low technical barriers by self inspection.Therefore,the management of T company determined to expanding business and develop more advanced technology products to match shared-bike,T company(Kunshan branch,i.e.Kunshan T company)was established accordingly.As a newly established small medium enterprise,Kunshan T company successfully developed and launched D602 bicycle DC dynamo which match shared-bike well in just a few months,amazingly quick operation! But some serious quality problems accompanied this high efficiency as well.According to statistics,the defect rate of the 3 major quality problem was as below: “voltage instability” is around 0.7%;“unable charge on bike”is around 1.3%;“rust on stator side surface(pawl)”.total defect rate is up to 14%.from 2017 Nov,starting mass production date to 2018 Apr,the direct quality cost for these 3 problems is RMB 150,000 and the indirect quality cost is up to 2,000,000.Based on the basic theory of quality management method and quality improvement technology to study D602,using PDCA method to discourse the quality improvement of products.Firstly,quality management existing condition of T company /basic situation of D602 /production process of D602 were represented,improvement goal was set as below 0.1%,after assessment,then a special transversal organization “Quality improvement committee” was set up and started to launch QC activity.Committee members discussed the 3 main quality problems by brainstorming method,and used fishbone diagram to analyze each one from 6 different side: man /machine /material /method /environment and measurement.The third step,all potential cause were found out,and corresponding improvement measures were formulated & carried out.Compared the latest defect rate 0.06% with the original goal(below 0.1%),Committee members believe it fully achieved the desired result after finished above steps.Finally,summed up the experience of this improvement activity and considering the orientation of next step improvement.The result of study for this article is not only reached the D602 quality improvement goal,but also be a profitable exploration for the others products in the whole T company,furthermore,it also supply those enterprise which produce similar small dynamos /motors likewise referential experience and operation method.