Study On Product Quality Improvement In Company R Based On DMAIC

Company R,headquartered in Belgium,is a foreign company specializing in the R&D,design,production and sales of Polyurethane(PU)spray for automotive interior products.With its advantages of good light stability,elastic sense of touch,ultra-low Volatile Organic Compounds(VOC)emission,lightweight,the products are widely used in automobile I-panel,door panel and other aspects,which are highly trusted by major automobile manufacturers.However,with the mass production of the project W and the improvement of various quality performance indicators,company R is facing a challenge of high Cost of Poor Quality(COPQ)caused by internal product defect.So it is urgent to improve product quality to reduce COPQ.In this thesis,Total Cost of Quality(TCOQ)performance is taken as the breakthrough point,and the main skin defect of Glove Box(GB)Skin is taken as an example,DMAIC(Define,Measure,Analyze,Improve and Control)improvement mode in Six-Sigma was applied.The existing problems of company R were analyzed and target was set for improvement.Then the key factors which affect GB skin damage were identified through Measurement System Analysis(MSA)and various data analysis.Afterwards the optimal improvement plan was defined according to the identified key factors.Finally,the control method was established to maintain the improvement results.During the research,Pareto analysis,flow chart analysis,MSA,regression analysis,hypothesis testing,statistical process control,process capability analysis and other tools were used in different stages.The ratio of COPQ to sales volume was reduced from annual average of 4.7% in 2017 to 1.2%,and the internal scrap rate was reduced to 0.78% from 2.57% in 2017,which brought saving of 1,303,523RMB/year for the company.Subsequently,the results were strengthen through standardized operation and documentation,and the experience was carried out to similar products,so that the experience gained from this improvement of this thesis could be applied in the same products of this factory and the other four factories in China,so that the production and management level of the company could reach a new level.The result of this study can be extended to other manufacturing companies.