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Minimization of Defective Products with Basic Statistical Process Control (SPC) Tools: A Case Study at Armament Parts Production Factory of Gafat Armament Industry - Ethiopa
Aragaw G/Medhin Meressa,
Lecture Department of Mechanical Engineering, Institute of Technology, Ambo University, Ethiopia
Article history: Received: 19 March, 2021
Accepted: 20 March, 2021
Available Online: 07 March, 2022
Abstract
The fast-changing economic conditions such as global competition, declining profit margin, customer demand for high quality product, product variety and reduced lead–time etc. had a major impact on manufacturing industries and defect rate of product plays a very important role for the improvement of yield and financial conditions of any company. Defect’s rate causes a direct effect on the profit margin of the product and companies strive to decrease the defects rate of the product during the manufacturing process as much as possible. Gafat Armament Industry is the one which faced this problem due to high defective/rejected product during the manufacturing process. The main objective of this thesis was to identify the root cause of critical problem and minimize the amount of defective product in the factory by applying basic statistical process control tools (SPC) and show how to reduce the problems by taking preventive action against any defects produced during the process. To meet these objectives the product with less annual performance and component with highest rejection rate were considered for detail analysis. The existing manufacturing system and the problem of APPF of GAI which are taken as a case for the study were assessed by collecting the data from both primary and secondary sources. In the analysis, it had been found that model ET-97/1 AKM 103 automatic rifles has less annual performance and Breechblock production line has the highest rejection rate. To alleviate the problems basic SPC tools like brainstorming session, Pareto analysis, control chart construction and cause and effect diagram construction are utilized. The analysis indicates; operator’s error (skill gap), machine tool problems, jigs and fixtures problems are the main root causes for rejection. Action plans were suggested and tested by applying model implementations and possible preventive actions and alternative solutions had been recommended for critical problems. Finally, this research paper introduced systematic way of finding the root causes of any production process and quality related problems, how to increase market competency and productivity as well as enhance profit by minimizing defective/rejected products of the factory under study using different Statistical Process Control (SPC) tools and capability analysis techniques.
Keywords:
Capability analysis, Cause-and-effect diagram, Control chart, Defect, Pareto analysis, Rejection, SPC.
Citation:
Aragaw G/Medhin Meressa, 2022. Minimization of Defective Products with Basic Statistical Process Control (SPC) Tools: A Case Study at Armament Parts Production Factory of Gafat Armament Industry -Ethiopa. Journal of Statistics. Photon 109, 136-154
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