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Metodologia DMAIC aplicada num processo produtivo de componentes eletrónicos
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O presente projeto descreve a aplicação da metodologia Define, Measure, Analyze, Improve e Control (DMAIC), integrada no Six Sigma, para resolver uma falha recorrente num sistema de deteção utilizado na montagem de autorrádios destinados a um cliente do ramo automóvel. O problema estava associado a montagens incorretas do conector principal que originava um defeito crítico, reclamações e risco para a certificação de qualidade. Ao longo das fases caracterizaram-se as fontes de variabilidade, avaliaram-se limitações do sistema de inspeção existente e recolheram-se dados que confirmaram baixa repetibilidade e insuficiente capacidade de deteção. Em colaboração com o fornecedor da máquina, foi concebido e implementado um novo sistema de visão baseado em medição direta, em que os resultados demonstraram melhorias do desempenho, nomeadamente a redução do DPMO de 36.82 para 18.41, sem registo de novas reclamações após a implementação. A análise económica evidenciou ainda um retorno do investimento inferior a dois anos. O projeto comprovou que o DMAIC é eficaz na redução da variabilidade e no reforço da fiabilidade do processo, sendo aplicável a outros sistemas produtivos da empresa.
This project describes the application of the Define, Measure, Analyse, Improve and Control (DMAIC) methodology, integrated into Six Sigma, to resolve a recurring fault in a detection system used in the assembly of car radios for a customer in the automotive industry. The problem was associated with incorrect assembly of the main connector, which caused a critical defect, complaints and a risk to quality certification. Throughout the phases, the sources of variability were characterised, the limitations of the existing inspection system were assessed, and data was collected that confirmed low repeatability and insufficient detection capability. In collaboration with the machine supplier, a new vision system based on direct measurement was designed and implemented, with results showing performance improvements, namely a reduction in DPMO from 36.82 to 18.41, with no new complaints recorded after implementation. The economic analysis also showed a return on investment of less than two years. The project proved that DMAIC is effective in reducing variability and enhancing process reliability, and is applicable to other production systems within the company.
This project describes the application of the Define, Measure, Analyse, Improve and Control (DMAIC) methodology, integrated into Six Sigma, to resolve a recurring fault in a detection system used in the assembly of car radios for a customer in the automotive industry. The problem was associated with incorrect assembly of the main connector, which caused a critical defect, complaints and a risk to quality certification. Throughout the phases, the sources of variability were characterised, the limitations of the existing inspection system were assessed, and data was collected that confirmed low repeatability and insufficient detection capability. In collaboration with the machine supplier, a new vision system based on direct measurement was designed and implemented, with results showing performance improvements, namely a reduction in DPMO from 36.82 to 18.41, with no new complaints recorded after implementation. The economic analysis also showed a return on investment of less than two years. The project proved that DMAIC is effective in reducing variability and enhancing process reliability, and is applicable to other production systems within the company.
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DMAIC Six Sigma Melhoria Contínua Sistema de Visão Indústria Automóvel Continuous Improvement Vision System Automotive Industry