Desenvolvimento de um sistema error proofing baseado no framework dmaic

Abstract

The increased demand for exclusive products with high quality and low cost has made companies innovate in their production processes. In the automotive industry, there are several manufacturing, assembly and tightening devices, and ensuring the quality of these processes ensures efficient production, adequate to the quality and safety programs required by law and by the consumer market. Despite the exponential growth in the use of new technologies in manufacturing processes, many companies still have several manual assembly processes and, therefore, are subject to the human factor and, consequently, to assembly errors. The error when not identified becomes a defect, this then a productive loss. Identifying, mitigating and preventing the spread of these defects is a common concept in many recent quality strategies. Therefore, the use of methodologies that help to improve processes is an effective practice and used by several industries. In this work, the DMAIC framework was used to conduct the development of an error proofing solution, to avoid assembly failures, as well as their propagation, aiming to reduce costs with non­quality. During the development of the work, three possibilities were identified for the development of the system, among them the acquisition of a corporate solution, the development of the system in partnership with a third­party company and the development of the system internally in the company. Thus, using the LabVIEW® programming language, a software that communicates efficiently with devices, mainly tightening tools and smart cameras was developed, in addition it communicates with the company systems, an essential resource for project success. Furthermore, the system reduces the worker’s cognitive load, using images and videos with translation into sign language for people with special needs, since training people to work in the sector digitized by industry 4.0 necessarily involves inclusion. The proposed solution, based on the DMAIC method, was successful in identifying assembly errors, interlocking processes and keeping traceability of assembly and failures. As a main result, the system identified 1013 defects in the first half of 2021 and achieved a reduction of defects per unit (DPU) by 43.3% in the first quarter of 2021, compared to the same period of the previous year, confirming the effectiveness of the proposed method.