Improving a Manufacturing Process Using the 8Ds Method. A Case Study in a Manufacturing Company
Customer satisfaction is a key element for survival and competitiveness in industrial companies. This paper describes a case study in a manufacturing company that deals with several customer complaints due to defective custom cable assemblies that are integrated in an engine. The goal of this resear...
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| Format: | Article |
| Language: | English |
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MDPI AG
2020-04-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/10/7/2433 |
| _version_ | 1797571599927345152 |
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| author | Arturo Realyvásquez-Vargas Karina Cecilia Arredondo-Soto Jorge Luis García-Alcaraz Emilio Jiménez Macías |
| author_facet | Arturo Realyvásquez-Vargas Karina Cecilia Arredondo-Soto Jorge Luis García-Alcaraz Emilio Jiménez Macías |
| author_sort | Arturo Realyvásquez-Vargas |
| collection | DOAJ |
| description | Customer satisfaction is a key element for survival and competitiveness in industrial companies. This paper describes a case study in a manufacturing company that deals with several customer complaints due to defective custom cable assemblies that are integrated in an engine. The goal of this research is to find a solution to this problem, as well as prevent its recurrence by implementing the eight disciplines (8Ds) method in order to: (1) develop a team, (2) describe the problem, (3) develop an interim containment action, (4) determine and verify root causes, (5) develop permanent corrective actions, (6) define and implement corrective actions, (7) prevent recurrences, and (8) recognize and congratulate teamwork as well as individual contributions. Therefore, a software tool is proposed to conduct a functional test on assembly lines. After the test, the problem was successfully reduced and detected, because from 67 engines that were identified with problems, 51 were redesigned before being sent to customers, consequently decreasing the number of defective products by 75%, whereas the remaining 16 engines were replaced by new engines. In conclusion, the research goal was accomplished, and the 8Ds method proved to be a helpful model with which to increase employees’ motivation and involvement during the problem-solving process. |
| first_indexed | 2024-03-10T20:43:01Z |
| format | Article |
| id | doaj.art-8099d7395f224297ad93b7b9af04d51d |
| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-03-10T20:43:01Z |
| publishDate | 2020-04-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj.art-8099d7395f224297ad93b7b9af04d51d2023-11-19T20:31:31ZengMDPI AGApplied Sciences2076-34172020-04-01107243310.3390/app10072433Improving a Manufacturing Process Using the 8Ds Method. A Case Study in a Manufacturing CompanyArturo Realyvásquez-Vargas0Karina Cecilia Arredondo-Soto1Jorge Luis García-Alcaraz2Emilio Jiménez Macías3Department of Industrial Engineering, Tecnológico Nacional de México/Instituto Tecnológico de Tijuana, Calzada del Tecnológico S/N, Tijuana 22414, Baja California, MexicoChemical Sciences and Engineering Faculty, Universidad Autónoma de Baja California, Calzada Universidad #14418, Parque Industrial Internacional, Tijuana 22390, Baja California, MexicoDepartment of Industrial and Manufacturing Engineering, Autonomous University of Ciudad Juarez, Ave. del Charro 450 Norte. Col. Partido Romero, Ciudad Juárez 32310, Chihuahua, MexicoDepartment of Electrical Engineering, University of La Rioja, Edificio Departamental—C/San Jose de Calasanz 31, 26004 Logroño, La Rioja, SpainCustomer satisfaction is a key element for survival and competitiveness in industrial companies. This paper describes a case study in a manufacturing company that deals with several customer complaints due to defective custom cable assemblies that are integrated in an engine. The goal of this research is to find a solution to this problem, as well as prevent its recurrence by implementing the eight disciplines (8Ds) method in order to: (1) develop a team, (2) describe the problem, (3) develop an interim containment action, (4) determine and verify root causes, (5) develop permanent corrective actions, (6) define and implement corrective actions, (7) prevent recurrences, and (8) recognize and congratulate teamwork as well as individual contributions. Therefore, a software tool is proposed to conduct a functional test on assembly lines. After the test, the problem was successfully reduced and detected, because from 67 engines that were identified with problems, 51 were redesigned before being sent to customers, consequently decreasing the number of defective products by 75%, whereas the remaining 16 engines were replaced by new engines. In conclusion, the research goal was accomplished, and the 8Ds method proved to be a helpful model with which to increase employees’ motivation and involvement during the problem-solving process.https://www.mdpi.com/2076-3417/10/7/24338 disciplines methodcustom cable assembliesdefectsfunctional testcustomer satisfaction |
| spellingShingle | Arturo Realyvásquez-Vargas Karina Cecilia Arredondo-Soto Jorge Luis García-Alcaraz Emilio Jiménez Macías Improving a Manufacturing Process Using the 8Ds Method. A Case Study in a Manufacturing Company Applied Sciences 8 disciplines method custom cable assemblies defects functional test customer satisfaction |
| title | Improving a Manufacturing Process Using the 8Ds Method. A Case Study in a Manufacturing Company |
| title_full | Improving a Manufacturing Process Using the 8Ds Method. A Case Study in a Manufacturing Company |
| title_fullStr | Improving a Manufacturing Process Using the 8Ds Method. A Case Study in a Manufacturing Company |
| title_full_unstemmed | Improving a Manufacturing Process Using the 8Ds Method. A Case Study in a Manufacturing Company |
| title_short | Improving a Manufacturing Process Using the 8Ds Method. A Case Study in a Manufacturing Company |
| title_sort | improving a manufacturing process using the 8ds method a case study in a manufacturing company |
| topic | 8 disciplines method custom cable assemblies defects functional test customer satisfaction |
| url | https://www.mdpi.com/2076-3417/10/7/2433 |
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