Redução de sucata em empresa fornecedora de autopeças utilizando a metodologia seis sigma

Abstract

The following study aims to apply the Six Sigma methodology to reduce scrap from the Eccentric Seat defect in the V-5991 valve, focusing on a cost reduction. To remain competitive in the market is necessary that production is in line with quality, also preventing defective products from reaching the end customer. Thus, it is necessary for the aid of tools contained in the Six Sigma methodology, identifying and eliminating causes that generate the defect. It is essential to study the process, raising potential causes and a comprehensive collection of data to identify the cause or points of anomalies by the tools available. The results of the application of this me thodology showed that the defect containment equipment (Poka-Yoke) was at odds with the process instruction, resulting in approval of parts with values above the limit tolerance. Besides, another feature coming from the friction welding process was not being controlled, causing the defect in the machining processes. Data analysis made it possible to define a new tolerance of 0.15 mm for the Poka-Yoke and, together with a configuration of parts standards for configuration, solved the problem of approval of ruined parts. The dimensions of the drawing of the Stripper tool were also changed, from 6.30 to 5.90mm, thus avoiding the production of parts with a flash diameter above the specified. Finally, it was possible to conclude that goal was achieved, exceeding the desirable scrap reduction by 29%, that is, from 1.89% to 1.16% per year. Thus, affirming the effectiveness of the tools and the conduct of the Six Sigma methodology.