Abstract
Despite the advancements witnessed in the realm of quality improvement, Statistical Process Control (SPC) perseveres as a universally embraced and extensively employed tool within manufacturing companies across the globe. This enduring popularity can be attributed to its adherence to the time-tested principles established by Shewhart, which have withstood the test of time since their inception in 1924. Over the years, SPC has consistently proven its efficacy in optimizing manufacturing processes, enhancing product quality, and fostering continuous improvement initiatives. Quality is an utmost necessity in the automotive industry, which ranks as the 3rd most significant industry in Mexico and the 5th globally in terms of volume and transactional activity. This research focuses on a successful real case study that demonstrates the enhancement of capability in a critical machining operation within an automotive plant located in Mexico, specifically dedicated to truck engine remanufacturing. This improvement was achieved through the analysis of x̅ and R control charts, followed by the implementation of the Plan-Do-Check-Act (PDCA) cycle. The results obtained were derived from a comparative analysis of data from two distinct time periods in the machining process of bushing diameters. This analysis revealed a significant increase in process capacity, with a 13.08% improvement in the Process Capability Index (Cpk) and a 17.2% enhancement in the Process Performance Index (Ppk). The decrease in expected out-of-specification parts showed a remarkable improvement of 72.7%. Additionally, there was an enhancement in process variability, with a notable 8.33% reduction in the mean range. The significance of this research lies in its empirical identification of gaps and opportunities within the realms of quality assurance and quality control, utilizing methodologies for quality improvement. By uncovering these gaps and opportunities, this study provides valuable insights that can guide future efforts to enhance quality practices and drive continuous improvement in the field.
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