Utilizing lean techniques through a P-D-C-A approach to drive built-in-quality in a thermoforming line for an automotive component manufacturer

Abstract

Automotive component manufacturers are faced with competitive challenges globally. At the heart of these challenges is the need to produce parts that are of high-quality standards. Now more than ever before, organizations need to work as a unit to drive the fundamentals of built in-quality if they are to maintain good quality standards and overall cost competitive leadership. An automotive component manufacturer was struggling with managing the thermoforming line outflow of defects to their customers. Substantial amounts of resources in the form of inspectors were being added on their manufacturing lines to form quality gates and inspect for quality. This has resulted in cost implications and major profitability losses and further expanded their cost of quality. The severity of the problem was further exacerbated by the acceptance of the quality gates as a status quo with little or no initiatives to turn around the situation. The aim of this study was to subdue the traditional quality management approach of inspecting for quality by introducing a series of lean manufacturing techniques that process capability and built-in quality. The study streamlined a sequence of lean manufacturing techniques that supported each other in their findings and results to develop a Plan-Do-Check-Act (PDCA) based strategic approach to drive in-process quality capability in the manufacturer’s Thermoforming line. The results of study were significant manpower reduction on the lines, improved quality capability results, reduced expected scrap rates and reworks, and an overall strategic guideline for the implementation of built-in-quality in automotive component manufacturer’s thermoforming line