Using DMAIC Methodology to Reduce Defects in Sport Bar Products

Abstract

The DMAIC process in Six Sigma technique was utilized for studying and analyzing to reduce defects in sport bar products. From gathering primary data, the major problem was on the products' surfaces accounted for 19.40%, included scratches, dent, pinhole and tool mark. The way to improve consisted of five phases, which were 1) Define: collect historical data to specify the scope of problem and use the Pareto chart to highlight important defects 2) Measure: identify and prioritize causes using failure mode and effects analysis (FMEA) 3) Analyze: detect root causes and develop possible actions from Why-why analysis 4) Improve: follow the guidelines, including material replacement for welding fixtures, new wrapping material during transport and work instruction for polishing machine, and 5) Control: summarize via standardizing the operating manual. After doing all five phases, the result found that the proportion of the defects decreased to be 2.5%. © 2019 IEEE.