Impact of Quality Control Tools for improving Manufacturing Performance

Abstract

The purpose of this study is to elaborate on the use of two out of seven QC tools of the quality management system to reduce rejection during operational and production stages in a car manufacturing company in northern India. After observing the process, it has been found that the tilting effort defect was causing major rejection, i.e., 26% rejection rates were observed. An eight-step methodology has been adopted to overcome the procedure of reducing quality rejection by defining the problem and removing the root cause of the problem using quality control tools, viz. the Pareto chart and run chart. Locking control of 2 nuts used in the steering wheel was achieved by the root cause analysis technique. Descriptive statistics (before and after root cause analysis) have been calculated, and validation of overall improvement is done by a two-tailed paired-sample t-test. With reduction in rejection, annual savings of 84000 rupees per annum have been made (rework cast savings of 7000 rupees per month). Finally, standard operating procedure has been prepared so that it becomes error-proof.