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Title Systematic Reduction of Component Rejects During the Assembly Process
Translated title Systematisk Reduktion i Antal Kasserede Emner Under Samleprocessen
Author Moody, Aaron (Copenhagen University College of Engineering, IHK)
Supervisor Schreiber, Mads Peter (Copenhagen University College of Engineering, IHK)
Institution Ingeniørhøjskolen i København, IHK, DK-2750 Ballerup, Denmark
Thesis level Bachelor thesis
Education Diplomingeniør, Maskiningeniør
Education Bachelor of Mechanical Engineering
Publication date 2013-06
Abstract The reduction of component rejection on an assembly line is an integral part of stabilizing the process. Excess waste translates into higher costs and lower efficiency. To successfully reduce the waste from the line, systematic problem solving tools must be implemented. For this project, the 5 phase DMAIC (Define-Measure-Analyze-Improve-Control) methodology was utilized to improve the assembly line rejection rate of the NovoPen5’s Dosage Selector Module during the ramp up phase prior to high-volume assembly. During the first phase, a clear definition of the goals, boundaries, and timeline was established in a project charter. Knowledge also had to be gained about the various parts and machines used in the assembly process. Once the project and process was clearly defined, the Measure phase was initiated, and the waste and cost gathering metrics were established. Data was gathered from the three assembly lines producing the component, and Pareto Charts were created. During the Analyze phase, the data was broken-down and compared so that the most problematic areas for rejection could be defined. Brainstorming was conducted, and three primary project focus areas were identified. Monitoring of the assembly process was then completed to gain further insight into what was causing the problems. Tests also had to be run to establish the exact problem details. Once details about the rejection areas was gained, the root causes were then found through further line monitoring, and the implementation of systematic problem solving tools such as a Cause-and-Effect Diagram and 5 why’s. When the root causes were established, the Improve phase started with identifying the potential improvements through both brainstorming and subsequent testing. Once the suggested improvements were outlined, the project was finalized, and the information was handed off so that the solutions could be incorporated into the assembly process.
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External partner Ledere og medarbejdere i private virksomheder
Admin Creation date: 2013-06-14    Update date: 2013-09-27    Source: ihk    ID: ihk-14844404    Original MXD