Application On Automotive Panel Assembly And Testing Production Line By DMAIC Method

The company Y is a world famous automotive electronics provider,its main products covers whole car cockpit electronics,such as driver information,audio infotainment and control system.To meet the need of continuous developing business and the quick change of the market,the company should solve different kinds of production issues and get more sustainable profits by an effective problem solving method.6Sigma management has been implemented in company Y for the last 11 years.During the great periods,6Sigma management has been an important continuous improvement way.Most of the people in company Y are familiar with 6Sigma.The 6Sigma saving rate to the revenue has been increasing year by year.DMAIC is the acronyms of define,measure,analyze,improve and control.DMAIC which is an important problem solving thinking method is a way for company Y to use 6sigma management.In this paper,company Y will use DMAIC method which is one way of 6Sigma management to solve high machine stoppage rate issue in A3 automotive panel assembly and testing production line.The method contains define phase,measure phase,analyze phase,improve phase and control phase.The task of define phase is to set the goals and team.In measure phase,the team will finish the measurement system analysis and find potential problem cause by process analysis.Quick win methods will be applied on the easy causes.In analysis phase,design of experiment and some statistical validated methods are the main means to find and prove the root causes of the machine stoppage problem.Improve phase task is to optimize the root cause proved during the analysis phase.Finally team not only monitors the result but also controls the problem causes to achieve and keep the improvement result.Achievement analysis indicate that the machine stoppage rate of A3 semi auto line has been decreased from 23.1% to 5% which realizes the goal set in the define phase.The article has summarized the problem solving method for the automotive panel and testing production line and the other similar production line by using DMAIC process improvement method applied on automotive electronic product.The results are also beneficial for the future lines and production setup.