Applying the Plan-Do-Check-Act (PDCA) Cycle to Reduce the Defects in the Manufacturing Industry. A Case Study
Source abstract
Abstract
Defects are considered as one of the wastes in manufacturing systems that negatively affect the delivery times, cost and quality of products leading to manufacturing companies facing a critical situation with the customers and to not comply with the IPC-A-610E standard for the acceptability of electronic components. This is the case is a manufacturing company located in Tijuana, Mexico. Due to an increasing demand on the products manufactured by this company, several defects have been detected in the welding process of electronic boards, as well as in the components named Thru-Holes. It is for this reason that this paper presents a lean manufacturing application case study. The objective of this research is to reduce at least 20% the defects that are generated during the welding process. In addition, it is intended to increase 20% the capacity of three double production lines where electronic boards are processed. As method, the Plan-Do-Check-Act (PDCA) cycle, is applied. The Pareto charts and the flowchart are used as support tools. As results, defects decreased 65%, 79%, and 77% in three analyzed product models. As conclusion, the PDCA cycle, the Pareto charts, and the flowchart are excellent quality tools that help to decrease the number of defective components.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Quality and Supply Management · Quality and Management Systems · Manufacturing Process and Optimization
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Department of Industrial Engineering, Tecnológico Nacional de México/Instituto Tecnológico de Tijuana, Calzada del Tecnológico S/N, Tijuana, Baja California 22414, Mexico
Chemical Sciences and Engineering Faculty, Universidad Autónoma de Baja California, Calzada Universidad #14418, Parque Industrial Internacional, Tijuana, Baja California 22390, Mexico
References (54)
Show source-provided references
1. (2018, October 03). Journal of Applied Sciences. Special Issue: Applied Engineering to Lean Manufacturing Production Systems. Available online: https://www.mdpi.com/journal/applsci/special_issues/aelmps.
2. Parag Real-Time Monitoring System to Lean Manufacturing10.1016/j.promfg.2018.02.019 ↗
3. How much does Lean Manufacturing need environmental and information technologies?10.1016/j.jmsy.2017.10.005 ↗
4. Integrating ergonomics and lean manufacturing principles in a hybrid assembly line10.1016/j.cie.2017.05.011 ↗
5. Lean product development and lean manufacturing: Testing moderation effects10.1016/j.ijpe.2018.07.009 ↗
6. Womack, J., Jones, D., and Roos, D. (1990). The Machine that Changed the World: The Story of Lean Production, Harper Perennial.
7. Implementing Lean Manufacturing Principle in Fabrication Process—A Case Study
8. Walder, J., Karlin, J., and Kerk, C. (2007). Integrated Lean Thinking & Ergonomics: Utilizing Material Handling Assist Device Solutions for a Productive Workplace, Material Handling Industry of America.
9. Influence of stochastic variations in manufacturing defects on the mechanical performance of textile composites10.1016/j.compstruct.2018.04.003 ↗
10. Compressive failure of fibre Composites10.1016/0022-5096(93)90068-Q ↗
11. Physically-based failure models and criteria for laminated fibre-reinforced composites with emphasis on fibre kinking: Part I: Development10.1016/j.compositesa.2005.04.016 ↗
12. Quantification of micro-scale variability in fibre bundles10.1016/j.compositesa.2016.04.019 ↗
13. Guiras, Z., Turki, S., Rezg, N., and Dolgui, A. (2018). Optimization of Two-Level Disassembly/Remanufacturing/Assembly System with an Integrated Maintenance Strategy. Appl. Sci., 8.10.3390/app8050666 ↗
14. Defect reduction in an electrical parts manufacturer: A case study10.1108/TQM-03-2018-0031 ↗
15. The contribution of lean manufacturing tools to changeover time decrease in the pharmaceutical industry. A SMED project10.1016/j.promfg.2018.03.125 ↗
16. An integrated continuous improvement model of TPM, TPS and TQM for boosting profitability of manufacturing industries: An innovative model & guideline10.5267/j.msl.2017.11.002 ↗
17. The Plan-Do-Check-Act Cycle of Value Addition Theory of constraint for continuous improvment View project
18. Ning, J., Chen, Z., and Liu, G. (2010, January 24–26). PDCA process application in the continuous improvement of software quality. Proceedings of the 2010 IEEE International Conference on Computer, Mechatronics, Control and Electronic Engineering, Changchun, China.
19. Proposta de aplicação do ciclo PDCA para melhoria contínua do sistema de confinamento bovino: Um estudo de caso
20. Application of Kaizen Concept with 8 Steps PDCA to Reduce in Line Defect at Pasting Process: A Case Study in Automotive Battery
21. Quality improvement methodologies—PDCA cycle, RADAR matrix, DMAIC and DFSS
22. IPC (2018, October 03). IPC-A-610E: Acceptability of Electronic Assemblies. Available online: http://shop.ipc.org/IPC-A-610E-English-D.
23. Strotmann, C., Göbel, C., Friedrich, S., Kreyenschmidt, J., Ritter, G., and Teitscheid, P. (2017). A Participatory Approach to Minimizing Food Waste in the Food Industry—A Manual for Managers. Sustainability, 9.10.3390/su9010066 ↗
24. PDCA and lean manufacturing: Case study in appliance of quality process in alpha graphics
25. Cleaner Production and PDCA cycle: Practical application for reducing the Cans Loss Index in a beverage company10.1016/j.jclepro.2017.03.033 ↗
26. PDCA as associated methodological Audit Health: Report of Sobral-Ceará
27. Implementing academic service learning and the PDCA cycle in a marketing course: Contributions to three beneficiaries
28. Maximizing Knowledge Work Productivity: A Time Constrained and Activity Visualized PDCA Cycle10.1002/kpm.1396 ↗
29. De Queiroz Albuquerque, A.C.R. (2015). Evaluation of the Application of the PDCA Cycle in Decision-Making in Industrial Processes, Federal University of Pará. (In Portuguese).
30. Zhang, X. (2013, January 21–22). The research and exploration about teaching reform. Proceedings of the Conference on Education Technology and Information System, Sanya, China.
31. A framework for effective six Sigma implementation10.1080/14783361003606720 ↗
32. Gorenflo, G., and Moran, J.W. (2009). The ABCs of PDCA, Public Health Foundation.
33. Quality management in Indian manufacturing organizations: Some observations and results from a pilot survey
34. Operational practices of lean manufacturing: Potentiating environmental improvements
35. Research on Integration Method of Integrated Management System10.2174/1874444301507011802 ↗
36. Design and Analysis of Tungsten Carbide Sludge Removal Machine for Maintenance Department in Cutting Tool Manufacturer10.1016/j.promfg.2017.07.269 ↗
37. Improving the Quality and Productivity of Steel Wire-rope Assembly Lines for the Automotive Industry10.1016/j.promfg.2017.07.214 ↗
38. Improving Quality of Light Commercial Vehicle
39. Bits Reduction in the Electrodeposition Process of a Pickup Truck: A Case Study
40. The PDCA Cycle Management Method in the Herceptin Usage Management Application
41. Minimization of Sewing Defects of an Apparel Industry in Bangladesh with 5S & PDCA
42. PDCA cycle as a part of continuous improvement in the production company—A case study10.30657/pea.2017.14.05 ↗
43. Implementation of model for improvement (PDCA-cycle) in dairy laboratories10.1111/jfs.12451 ↗
44. Theory Driven Real Time Empirical Investigation on Joint Implementation of PDCA and 5S for Performance Improvement in Plastic Moulding Industry
45. Joiner Associates Staff (1995). Pareto Charts: Plain & Simple, Oriel Incorporated.
46. Investigation of the Accidents Recorded at an Emergency Management Center Using the Pareto Chart: A Cross-Sectional Study in Gonabad, Iran, During 2014–201610.29252/nrip.hdq.3.3.143 ↗
47. Webber, L., and Wallace, M. (2011). Quality Control for Dummies, John Wiley & Sons.
48. Joiner Associates Staff (1995). Introduction to the Tools: Plain & Simple: Learning and Application Guide, Oriel Incorporated.
49. Application of Quality Tools in a Plastic Based Production Industry to achieve the Continuous Improvement Cycle
50. An Application of PARETO Chart for Investigation of Defects in FNB Casting Process
51. Investigation of Shrinkage Defect in Castings by Quantitative Ishikawa Diagram10.1515/afe-2017-0032 ↗
52. Implementation of Quality Control Tools and Techniques in Manufacturing Industry for Process Improvement
53. Improving Quality of Light Commercial Vehicle Using PDCA Approach
54. Joiner Associates (1995). Flowcharts: Plain and Simple, Oriel Incorporated.