PRODUCTIVITY IMPROVEMENT OF HIGH END CNC MACHINES BY DMAIC METHODOLOGY

Abstract

This research mainly emphasizes on productivity improvement with the application of DMAIC (Define, Measure, Analyze, Measure, Improve, Control) which is sub methodology of Six Sigma. It shows the application of Six Sigma in Auma India Pvt. Ltd. to reduce the cycle time and set-up times of High End CNC machines. At Auma, one of the most critical problem is that the existing production rate cannot meet the customer demands. This work was focused on improving the production rate of CNC machines without sacrificing on quality and to improve output and productivity of the whole machining station. The main problem regarding the production rate lies in long cycle time in machining station. Cycle time determine downtime, capacity, product quality, and to some extent costs. The other problem is related to the long cycle time of various components. This project implements Six Sigma methodology-DMAIC proposes a set of solutions, such as set up sequence optimization, set up operation simplification, to reduce set up time without sacrificing quality. Productivity per month was improved from 71% to 75%. Future recommendations were also provided that would further increase productivity.