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Application of Kaizen Lean approach to reduce rejections and failure cost at Shop floor of a wire harness manufacturing company

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Title Application of Kaizen Lean approach to reduce rejections and failure cost at Shop floor of a wire harness manufacturing company
 
Creator Kumar, Pramod
Singh, Dharmendra
Bhamu, Jaiprakash
 
Subject Kaizen
Root cause analysis
Failure cost
Process improvement
Rejection level
 
Description 116-123
Kaizen is a basic tool of lean manufacturing which is useful for better improvement and cost effectiveness in different
organizations. This study describes a sequential method that uses kaizen continuous improvement approach to eliminate the
lock release problem of band harness in a Wire Harness Manufacturing unit. Due to releasing of this self-locking type tie band,
wire harness was not holding properly against the bracket and wires were not properly tightened which results in high rejection
level of the product. Further, it also affects overall quality rating and increasing the rework cost significantly. In present study
four problems which are responsible for rejections, are identified through brainstorming. Pareto analysis and rating method are
used to know the major problem, responsible for highest rejections and why-why analysis is used to find out the root cause of
the identified problem. To eliminate this cause, step by step procedure based on lean manufacturing approach, is applied in the
case company. Statistical quality control tools are also used to analyze the problem. This study results in total cost saving of
535.20 $ per annum and beyond this some other tangible or intangible benefits were also observed.
 
Date 2022-04-06T09:26:31Z
2022-04-06T09:26:31Z
2022-02
 
Type Article
 
Identifier 0975-1017 (Online); 0971-4588 (Print)
http://nopr.niscair.res.in/handle/123456789/59464
 
Language en
 
Publisher NIScPR-CSIR, India
 
Source IJEMS Vol.29(1) [February 2022]