Abstract
Six Sigma is a systematic improvement method, a management approach designed to continuously improve corporate business processes and achieve customer requirement. This paper presents a case study conducted at a cell phone manufacturing company that intended to use the DMAIC method to carry out a structured approach to Six Sigma projects with fewer defective units generated by the cell phone hot press in process. In this process, Boss cracking and torque force failure led to high scrap costs and line downtime, which ultimately affected the supply of the assembly line. To this end, the Six Sigma approach was applied starting with the problem being defined, measured, and exhaustively analyzed to determine the root cause: poor injection molding structure, metal insert not perpendicular to the hole, improperly set molding machine parameters, and core/cavity dimension variation. A series of improvement measures addressing these factors increased the quality level of the process by improving the mold design to increase venting, optimizing the product structure to add the guide chamfer, and developing a standardized molding parameter setup procedure. Methods to maintain process control were also identified and implemented. The use of several quality tools and the use of Six Sigma methods also made the process more consistent.
Highlights
Due to constant changes in customer needs, new markets, innovations and other external factors, organizations are under constant pressure to improve the quality of their existing processes and to develop new processes to meet market trends
This paper describes a project undertaken by a cell phone manufacturing company whose goal was to use Six Sigma methods to reduce the number of defective cells in a process that is a common part of cell phone manufacturing: the hot press in process
It has been found that in the hot press in process, if the process parameters are not set properly there are cosmetic defects such as failure of torque force or even cracking and higher scrap costs and reduced productivity, which affects the supply of the final assembly line
Summary
Due to constant changes in customer needs, new markets, innovations and other external factors, organizations are under constant pressure to improve the quality of their existing processes and to develop new processes to meet market trends. For this purpose, powerful methods of quality management, such as Six Sigma [1][2][3], can be used. It has been found that in the hot press in process, if the process parameters are not set properly there are cosmetic defects such as failure of torque force or even cracking and higher scrap costs and reduced productivity, which affects the supply of the final assembly line. The final section presents the conclusions of the implementation of the methodology in the hot press in process
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