Investigation and implementation of 8D methodology in a manufacturing system

Abstract

The micro, small, and medium-sized business (MSMEs) industry is the economy's growth engine. Micro-Small and Medium Enterprises have a greater Labour strength than large businesses. Micro-Small and Medium Enterprises account for most jobs in any sector. Waste reduction, quality improvement, time management, environmental sustainability, and growth measures are all major issues for Micro-Small and Medium Enterprises. As a result, any business needs a good team and a long-term business model to succeed. One of the most reliable designs for product and quality development, waste reduction, and problem-solving is the 8Ds methodology. As a result, the goal of this 8Ds methodology is to adopt and investigate a simple sustainable work method that aids in the reduction of time decay and waste. Micro-Small and Medium Enterprises have a high rate of manufacturing defects, which leads to company failure and a decline in sales and revenue. The 8Ds work method entails forming a proactive team to tackle these questions. The primary goal of this research paper is to identify a problem with both the gearbox and vibrator in the well-known tobacco industry and to use the Eight Disciplines(8D) methodology to minimize breakdown time and repair costs of the machinery. All these details were gathered from various industrial processes to research and evaluate the 8d methodology. The 8d approach, root cause analysis, and fishbone diagram were also used to solve the problem described above. After changing the gear material and using lubricants between the gear and the vibrator, the breakdown time was reduced. Following a successful implementation of the changes, the break manufacturing time of the tobacco bundle was reduced by 29 percentage and defects were reduced by 72 percentage as well as the equipment cost of maintenance.