Abstract

The goals of this research were to identify problems, find solutions and implement DMAIC to improve the high defect rate in weaving process that was causing high operation cost at Wire Harness Tape Manufacturing in Thailand. In this study, qualitative research was used with samples were collected, and the paper gives an insight into the 16-week journey of applying a DMAIC (Define-Measure-Analyze-Improve-Control) of Six Sigma framework to achieve the purposes of reduction in weaving process. The study has utilized the Six Sigma tools such as brainstorming, SIPOC, affinity diagram, Isikawa diagram, Pareto chart and checklist. As a result, the root cause of significant defects as, first, the human problem was defined, human error, no motivation, not enough training. Then an improvement plan was constructed, it included training of SOP, ISO 9001:2015, and CTQs. Next, the machine problem also was defined, with the machine that was in inappropriate condition always breakdown and spare part shortage. the preventive maintenance, daily checking, and monthly scheduled maintenance will vanish these issues accordingly. Last, the raw material issue, the lack of full inspection, lack of vendor site inspection, and not qualified products, those issues can prevent action by the system of value chain management and supplier relationship management with vendor site inspection planning respectively. Although, the ISO 9001:2015 is the significance tool implementation to ensure the company meets quality control and quality assurance. In the end, we have been able to achieve the desired reduction of 6% to zero defect rate. The value of this study presents an industrial case that demonstrates how the deployment of Six Sigma and DMAIC can assist manufacturing productivity to achieve quality improvements in their processes.

Keywords: Six Sigma, DMAIC, Defect Reduction, Wire Harness Tape, Process of Product Quality Control