DEFECTS MINIMIZATION USING DESIGN OF EXPERIMENT BASED DMAIC APPLICATION: A CASE OF ROYAL PVC

Abstract

Currently there is 19% rejection in manufacturing occurring due to poor quality. The data was collected and Pareto analysis ranked the defects in descending order according to their counts. The major factors identified are materials composition, temperature of extruder machine, speed of the pull conveyer and feed rate of the motor. ANOVA for diameter is analyzed against the compositions and temperature of the extruder machine. Both samples were rejected based on software results and shown that the variation is uniform. Color failure analysis is based on verbal communication with dealers and SMEs at site work. In the improvement phase, two levels were selected for each factor (temperature, feed rate and conveyer speed) and the experiment is designed as three factors factorial design. Main effect and interaction effects were identified and consequently, the conveyer speed and the interaction of temperature and feed rate (2-way interaction) were found to be significant factors.

Keywords

• pvc
• dmaic
• quality control
• design of experiment (doe)
• anova.