Root Cause Assessment for a Manufacturing Industry: A Case Study

Abstract

Root-cause identification for quality related problems are key issues for manufacturing processes. It has been a very challenging engineering problem particularly in a multistage manufacturing, where maximum number of processes and activities are performed. However, it may also be implemented with ease in each and every individual set up and activities in any manufacturing process. Kaizen is aimed towards reduction in different types of losses i.e. Failure Loss/ Breakdown Loss, Minor stoppage, idling loss, Setup and adjustment loss etc. So as to improve quality and productivity.In this report, root-cause identification methodology has been adopted to eliminate the rejection of product manufactured by the enterprise and improving the life of product. Brainstorming and other Root Cause Assesmenttools have been used to find out the reasons of tube failure and vibration in tubular strander. Solutions of these problems have also given in this report. Kaizen activities have reduced the time consumed in daily activities of cleaning, lubricating, inspection etc. A detailed study has illustrated the effectiveness of the proposed methodology.

Keywords

• RCA(Root Cause Assesment) CED(Cause Effect Diagram)TQM(Total Quality Management) SR(Stress Relieving)PIA(Principle Inertia Axis).