Abstract
Lower air gap in ceiling fan motors leads to higher rework at an assembly. It is suspected that inappropriate component design specifications may be the root cause. To resolve the issue and prevent worker dissatisfaction, a study is undertaken to evaluate the extent of air gap variation when components are produced as per design. First air gap is modeled as a function of different parameters of a fan assembly. The theoretical probability distribution of this modeled air gap function, though not impossible to obtain, is quite complex to derive. Thus this model is then used to generate data on air gap using Monte Carlo simulation. Analysis of the data shows that lack of process capability, not inappropriate design specifications, is mainly responsible for higher rework. The findings were discussed with management and were accepted. As a sequel to the study, a cost-benefit analysis is being undertaken for procuring new and improved machines.
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