Application of pareto analysis and cause-and-effect diagram (CED) in minimizing raw material rejection in lamp production

Abstract

Manufacturing processes tend to produce operational wastages due to various reason" which can he reduced by identifying and eliminating (hos~ reasons. It has been a very challenging engmeenng problem particularly in a multistage lll[lJ]ufacturing, where maximum number of processes and activities are performed. This has the effect of undercutting output gro\\.th ~ia the procurement offactor inputs as expenditure on otT-shore inpllts which constitute a large chunk or total inputs, will have to be cut back significantly Thus to trigger and sU8lain grov.th momentum, productivity enhancement is absolutely criticaL An electric GLS lamp has five main raw materials such as Flange lLlbc, G1a<;~~hell, J .eau in Wire (LI\V), Filament (Coil) and Cap. I'his thesis, the production belt HHH-J i~ studied over the period of January,201 0 to December,2010 and collects the defeet~ of the stem making, mount making, ~ealing, pnmp and capping proees, from the bin count logbook. The Pareto diagrams is n,>edto identify critical area~ of rejection, (he manufactUilng process defccts in thc each stage of the production belt have been prioritized by arranging them in decreasing order of importance in terms of quantities of defect type in the respective stagc of the belt. Then eau~e and ell;,cl diab'fam is being applied to explore possible canses/factors of defects and to determine (he cause8iTactor" which has (he greatest effect. In this paper, systematic methodology is ulilized a( the factory level by finding the root causes of defects in stem making, mount making, sealing, pump and capping stage. The integration Pareto analysis with CEO i~used 10 facilitate rapid analysis of manufacturing defects at different stage oflhe production belt which will explore the lamp manufacturing system productivity and the in\'estigation of productivity improvement 0pp0rllinities.